Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Transfer Assembly Inspection
- Raise the vehicle on a lift, and make sure it is supported securely.
- Shift the transmission into N.
- Make a reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C).
- Separate the No. 1 propeller shaft from the transfer assembly.
- Set a dial indicator (A) on the transfer companion flange (B), and measure the transfer gear backlash.
Standard: 0.06-0.16 mm (0.002-0.006 in.)
- If the backlash is out of standard, remove the transfer assembly, and adjust the transfer gear backlash (see step 20 on REASSEMBLY ).
- Check for fluid leaks between the mating surfaces of the transfer assembly and transmission.
- If there is a leak, remove the transfer assembly, and replace the O-ring. Also check for fluid leaks between the mating surfaces of the transfer housing and transfer cover. If there is a leak, remove the transfer assembly, and replace the O-ring.
- Check for leaks between the transfer companion flange and transfer oil seal.
- If there is a leak, remove the transfer assembly from the transmission, and replace the transfer oil seal and O-ring on the transfer output shaft. If oil seal and O-ring replacement is required, you will need to check and adjust the transfer gear tooth contact, transfer gear backlash, the tapered roller bearing starting torque, and the total starting torque (see INSPECTION ). Do not replace the oil seal with the transfer assembly on the transmission.
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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