Transmission-To-Transfer Case End Play Check

NOTE: ATF circulates between transaxle and transfer case. In situations where transaxle related failures circulate debris into transfer case, transfer case must be disassembled, cleaned, and inspected for damage.

1. Position transaxle so case side cover is facing down. Install final drive sun gear shaft. See Figure. Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. See Figure. Install final drive sun gear. See Figure.
2. Install bolts to end play checking tool and tighten securely to prevent tool deflection during end play measurement. See Figure. Hand tighten end play checking tool to remove end play. Install gauge bar onto case mounting surface.
3. Measure distance from case mounting surface, bottom of gauge bar to top of final drive sun gear. See Fig 1. This measurement is dimension "A". Remove gauge bar and end play checking tool.
4. Install gauge bar onto carrier. Measure distance from bottom of gauge bar to transfer case. See Fig 2. This measurement is Dimension B1. Measure distance from bottom of gauge bar to thrust bearing. See Fig 3. This measurement is Dimension B2. Subtract Dimension B2 from Dimension B1. This is Dimension "B". For available thrust washer sizes, refer to illustration. See Fig 4.
5. Remove gauge bar from transfer case. Remove final drive sun gear. Install selective washer. See Figure. Install final drive sun gear. See Figure.

Fig 1: Checking Transaxle-To-Transfer Case End Play (1 Of 3)

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Fig 2: Checking Transaxle-To-Transfer Case End Play (2 Of 3)

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Fig 3: Checking Transaxle-To-Transfer Case End Play (3 Of 3)

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Fig 4: Transfer Case Selective Washer Specifications

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