DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
| Condition | Possible Cause | Correction |
|---|---|---|
| Transfer case difficult to shift or will not shift into desired range. | 1) Transfer case electronically controlled shift system malfunction. | 1) Check for Transfer Case DTCs. Refer to appropriate TRANSFER CASE Electrical Diagnostics article and depending on vehicle configuration (FCM, FDCM, or DTCM), perform the appropriate diagnostic procedure and verification test. |
| 2) If vehicle was operated for an extended period in 4HI mode on dry surface, driveline torque load may cause difficulty. | 2) Drive the vehicle in a straight line and momentarily release the accelerator. The transfer case can then be shifted to the desired mode. | |
| 3) Insufficient or incorrect lubricant. | 3) Drain and refill transfer case with the correct quantity of Mopar® ATF +4, Automatic Transmission Fluid. | |
| 4) Internal transfer case components binding, worn, or damaged. | 4) Repair or replace components as necessary. | |
| Transfer case noisy in all drive modes. | 1) Insufficient or incorrect lubricant. | 1) Drain and refill transfer case with the correct quantity of Mopar® ATF +4, type 9602, Automatic Transmission Fluid. |
| 2) Internal transfer case components binding, worn, or damaged. | 2) Repair or replace components as necessary. | |
| Transfer case noisy while in, or jumps out of, 4LO mode. | 1) Transfer case not completely engaged in 4LO position. | 1) While rolling 2-3 MPH and the transmission in NEUTRAL, shift transfer case to the 2WD or 4HI position, and then back into the 4LO position. |
| 2) Range fork damaged, inserts worn, or fork is binding on the shift rail. | 2) Repair or replace components as necessary. | |
| 3) Low range gear worn or damaged. | 3) Repair or replace components as necessary. | |
| Lubricant leaking from transfer case seals or vent. | 1) Transfer case overfilled. | 1) Drain lubricant to the correct level. |
| 2) Transfer case vent closed or restricted. | 2) Clean or replace vent as necessary. | |
| 3) Transfer case seals damaged or installed incorrectly. | 3) Replace suspect seal. | |
| Abnormal tire wear. | 1) Extended operation in 4HI mode on dry surfaces | 1) Operate vehicle in 2WD mode on dry surfaces. |
DIAGNOSIS CHART
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone. However, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
Scheme 3
| 1 - PLANETARY CARRIER | 4 - CARRIER LOCK RING |
|---|---|
| 2 - REAR THRUST WASHER | 5 - CARRIER LOCK RETAINING RING |
| 3 - FRONT THRUST WASHER | 6 - INPUT GEAR |
Check the teeth on the input gear (6). (Scheme 3) Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery cloth if necessary.
Examine the planetary carrier body (1) and pinion gears for wear or damage. The carrier will have to be replaced as an assembly if the body, pinion pins, or pinion gears are damaged.
Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.
Scheme 4
| 1 - RANGE FORK |
|---|
| 2 - MODE FORK AND RAIL |
| 3 - MODE SPRING |
Check condition of the shift forks and mode fork shift rail (2). (Scheme 4) Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.
Scheme 5
| 1 - RANGE FORK |
|---|
| 2 - MODE FORK |
| 3 - WEAR PADS (SERVICEABLE) |
| 4 - WEAR PADS (SERVICEABLE) |
Inspect the shift fork wear pads (3, 4). (Scheme 5) The mode (2) and range (1) fork pads are serviceable and can be replaced if necessary.
Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.