2002 Chrysler Intrepid BaseFACTORY OEM SERVICE PROCEDURE

Transfer System: Inspection

The need to replace the transfer chains because of excessive wear is unlikely. If chain length is suspected to be long, perform the following procedure to measure the chain length:

  1. Insert a screwdriver into the 18 mm hole with the screwdriver ABOVEΒ  the chains. See Fig 1.
    Fig 1: Identifying Screwdriver Placement
    G00991901Courtesy of DAIMLERCHRYSLER CORP.
  2. Pry the chains down at the center of the chains.
  3. Butt a scale against the snubber and mark the scale at the bottom of the chains. See Fig 2.
    Fig 2: Measuring Chain
    G00991902Courtesy of DAIMLERCHRYSLER CORP.
  4. Insert a screwdriver into the 18 mm hole with the screwdriver BELOWΒ  the chains. See Fig 3. An assistant may be needed to perform this step.
    Fig 3: Identifying Screwdriver Placement
    G00991903Courtesy of DAIMLERCHRYSLER CORP.
  5. Pry the chains up at the center of the chain.
  6. Butt a scale against the snubber and place a second mark on the scale at the bottom of the chains. See Fig 4.
    Fig 4: Measuring Chain
    G00991904Courtesy of DAIMLERCHRYSLER CORP.
  7. Measure the distance between the two marks placed on the scale. See Fig 5. If the two marks on the scale are more than one inch apart, replace the drive chains.
    Fig 5: Measuring Marks on Scale
    G00991905Courtesy of DAIMLERCHRYSLER CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.