Transfer Assembly Inspection

Using a micrometer, measure the diameter of the transfer input shaft journal surface.

Minimum diameter:

47.59 mm (1.8737 in.)

Using a dial indicator, measure the inside diameter of the transfer input shaft bushing.

Maximum inside diameter:

39.14 mm (1.5409 in.)

While pushing in the front transfer drive clutch synchronizer ring, try to turn the ring in both directions. Check that the ring cannot be rotated.

Using a feeler gauge, measure the clearance between the front transfer drive clutch synchronizer ring and transfer input shaft spline.

Standard clearance:

1.05 to 1.85 mm (0.0414 to 0.0728 in.)

Minimum clearance:

1.05 mm (0.0414 in.)

Using a feeler gauge, measure the thrust clearance of the pinion gear.

Standard clearance:

0.11 to 0.84 mm (0.00434 to 0.0330 in.)

Maximum clearance:

0.84 mm (0.0330 in.)

Using a dial indicator, measure the radial clearance of the pinion gear.

Standard clearance:

0.009 to 0.038 mm (0.000355 to 0.00149 in.)

Maximum clearance:

0.038 mm (0.00149 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Maximum clearance:

0.25 mm (0.00984 in.)

Using a micrometer, measure the diameter of the rear transfer output shaft journal surface.

Minimum diameter for A:

27.98 mm (1.1016 in.)

Minimum diameter for B:

36.98 mm (1.4561 in.)

Using a dial indicator, measure the radial clearance between the drive sprocket and output shaft with the needle roller bearing installed.

Standard radial clearance:

0.010 to 0.055 mm (0.000394 to 0.00216 in.)

Maximum radial clearance:

0.055 mm (0.00216 in.)

Using a feeler gauge, measure the clearance between the clutch sleeve and No. 2 gear shift fork.

Maximum clearance:

0.25 mm (0.00984 in.)

Using a feeler gauge, measure the clearance between the clutch sleeve and No. 1 gear shift fork.

Maximum clearance:

0.25 mm (0.00984 in.)