NEW PROCESS MODEL 241
An identification tag is attached to the rear case half. The tag provides the transfer case model number, low range reduction ratio and assembly part number.
BORG-WARNER MODELS 1370 & 4470
An identification tag is attached to an extension housing bolt. The tag provides the transfer case model number, serial number, build date and low range reduction ratio.
FOUR WHEEL DRIVE DOES NOT ENGAGE
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Blown A/C-HTR Fuse. | Replace. |
| Faulty transfer sw. | Replace. |
| Faulty 4WD Indicator light, sw, or wiring (4WD engaging but indicator light not coming on. | Repair as needed. |
| Transfer case linkage improperly adjusted or disconnected. | Adjust or repair. |
| Faulty transfer case: Drive chain broken, range selector ring broken | Repair |
| Faulty front axle. | Repair |
TRANSFER CASE DIAGNOSIS
FOUR WHEEL DRIVE ENGAGES BUT INDICATOR LAMP WILL NOT LIGHT
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Blown bulb. | Replace. |
| A/C-HTR fuse blown. | Replace. |
| Faulty front axle sw. | Replace. |
| Faulty wiring. | Repair open in wiring. |
FOUR WHEEL DRIVE ENGAGES BUT INDICATOR LAMP WILL NOT LIGHT
4WD INDICATOR LIGHT WON'T TURN OFF (4WD DISENGAGES PROPERLY)
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Faulty front axle sw. | Replace. |
4WD INDICATOR LIGHT WON'T TURN OFF (4WD DISENGAGES PROPERLY)
FOUR WHEEL DRIVE WILL NOT DISENGAGE
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Faulty wiring or front axle sw. (4WD disengaging but indicator light staying on). | Replace or repair wiring. |
| Transfer case linkage binding or improperly adjusted. | Replace or repair. |
| Faulty front axle shift mechanism. | Repair |
FOUR WHEEL DRIVE WILL NOT DISENGAGE
JUMPS OUT OF FOUR WHEEL DRIVE
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Transfer case linkage binding or improperly adjusted. | Replace. |
| Worn or damaged engine or trans. mountings. | Replace |
| Transfer case mounting bolts loose | Tighten. |
| Drive shaft slip splines dry or loose. | Lubricate or replace |
| Transfer case or front axle internal problem. | Repair |
JUMPS OUT OF FOUR WHEEL DRIVE
TRANSFER CASE SHIFT LEVER HARD TO SHIFT OR WON'T SHIFT INTO 4 LOW OR NEUTRAL (VEHICLE MOVING)
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Vehicle in motion when attempting to shift. Stop vehicle when shifting into or out of 4 "LO" or "NEUTRAL". or wiring (4WD engaging but indicator light not coming on. | None is required. |
SHIFT LEVER HARD TO SHIFT OR WON'T SHIFT INTO 4 LOW OR NEUTRAL (VEHICLE MOVING)
TRANSFER CASE DIFFICULT TO SHIFT
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| In extremely cold weather, it may be necessary to reduce vehicle speed or stop before shifting from 2 Wheel to 4 High. indicator light not coming on. | None is required. |
| If vehicle has been operated for an extended period in 4 High mode on dry pavement, difficult shifting may result due to driveline torque lock. Stop vehicle, shift transmission to neutral and shift transfer case into desired mode. | Operate vehicle in 2 WHEEL mode on dry pave- ment. Oversize under-inflated tires may also cause torque. |
| Transfer case linkage binding. | Adjust or repair. |
| Low transfer case lubricant level or improper lubricant used. | Fill with proper lubricant. |
| Internal transfer case problem. | Repair. |
| Faulty wiring or electronic synchronizer (Models 1370 & 4470) | Test as outlined later & repair as needed. |
TRANSFER CASE DIFFICULT TO SHIFT
TRANSFER CASE NOISY IN ALL MODES
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Low lube level, or improper lubricant used. | Fill with proper lubricant. |
| Worn, under-inflated or over-sized tires. | Replace or inflate. |
| Internal transfer case problem. | Repair. |
TRANSFER CASE NOISY IN ALL MODES
NOISY IN OR JUMPS OUT OF 4 LOW RANGE
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Transfer case not completely engaged in 4 LOW range. Stop vehicle, shift into NEUTRAL, then back to 4 LOW. | None required. |
| Shift linkage loose or binding. | Repair. |
| Transfer case internal shift mechanism faulty. | Repair or replace. |
NOISY IN OR JUMPS OUT OF 4 LOW RANGE
LUBRICANT LEAKING FROM TRANSFER CASE VENT
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Transfer case overfilled. | Drain lubricant to proper level. |
LUBRICANT LEAKING FROM TRANSFER CASE VENT
LUBRICANT LEAK AT OUTPUT SHAFT SEALS
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Transfer case overfilled. | Drain lubricant to proper level. |
| Vent hose plugged or kinked. | Repair. |
| Output shaft seals damaged or incorrectly installed. | Replace. |
LUBRICANT LEAK AT OUTPUT SHAFT SEALS
ABNORMAL FRONT TIRE WEAR
| POSSIBLE CAUSE | CORRECTION |
|---|---|
| Front end needs alignment. | Align to specifica- tions. |
| Extended operation on hard, dry surfaces in 4 HIGH mode. | Operate vehicle in 2 WHEEL mode on hard, dry surfaces. |
ABNORMAL FRONT TIRE WEAR
ELECTRONIC SYNCHRONIZER SYSTEM CHECK (1370 & 4470 ONLY)
- Place ignition switch in RUN position, with 4WD engaged. It may be necessary to rotate the front tires slightly for the front axle to fully engage.
- Electronic synchronizer connector at the transfer case. Connect a test lamp from the wiring harness read wire connector ground. The test lamp should light.
- If the test lamp does not light, check the ckt. for opens. If none are found, replace the relay as outlined later.
- If the test lamp lights in step 2, check the synchronizer coil for continuity. If the coil is open, replace it. If the synchronizer coil has continuity, it is probably OK. Recheck fluid levels, linkage adjustments, etc. before presuming the synchronizer to be faulty.