Transfer Assembly Inspection

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

Minimum diameter:

47.59 mm (1.88 in.)

Using a feeler gauge, measure the thrust clearance of the planetary 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 planetary 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 micrometer, measure the outer diameter of the output shaft rear journal surfaces.

Standard diameter:

Journal A:

27.98 to 27.99 mm (1.1015 to 1.1019 in.)

Journal B:

31.98 to 32.00 mm (1.2591 to 1.2598 in.)

Journal C:

34.98 to 35.00 mm (1.3772 to 1.3779 in.)

Journal D:

36.98 to 37.00 mm (1.4560 to 1.4566 in.)

Minimum diameter:

Journal A:

27.98 mm (1.1015 in.)

Journal B:

31.98 mm (1.2591 in.)

Journal C:

34.98 mm (1.3772 in.)

Journal D:

36.98 mm (1.4560 in.)

Using a vernier caliper, measure the thickness of the shift fork claw.

Standard thickness (A):

10 mm (0.394 in.)

Using a vernier caliper, measure the width of the groove of the high and low clutch sleeve.

Standard width (B):

10.5 mm (0.413 in.)

Calculate the clearance between the high and low clutch sleeve and shift fork.

Standard clearance (B) - (A):

0.26 to 0.84 mm (0.0103 to 0.0330 in.)

Maximum clearance (B) - (A):

0.84 mm (0.0330 in.)

Using a vernier caliper, measure the thickness of the center differential lock fork claw.

Standard thickness (A):

10 mm (0.394 in.)

Using a vernier caliper, measure the width of the groove of the front drive clutch sleeve.

Standard width (B):

10.5 mm (0.413 in.)

Calculate the clearance between the front drive clutch sleeve and differential lock fork.

Standard clearance (B) - (A):

0.26 to 0.84 mm (0.0103 to 0.0330 in.)

Maximum clearance (B) - (A):

0.84 mm (0.0330 in.)

Check that the splines of the clutch sleeve are not worn.

Install the clutch sleeve to the center differential case and check that the clutch sleeve moves smoothly.

Check that the splines of the clutch sleeve are not worn.

Install the clutch sleeve to the center differential case and check that the clutch sleeve moves smoothly.