Transmission to Transfer Case End Play Check F4WD Only

Important: Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. Refer to Internal Components Cleaning and Inspection .

1. Position the transaxle so that the case side cover is facing down.
2. Install the final drive sun gear shaft (689).




Notice: The park gear thrust bearing (695) must be retained in the park gear (696) when installing the transfer case to the transmission, or damage may occur.

3. Use J 36850 or equivalent in order to retain the parking gear thrust bearing (695) to the parking gear (696).

Install the parking gear thrust bearing (695) and the parking gear (696).





Important: The counterbore on the final drive sun gear installs towards the parking gear.

4. Install the final drive sun gear (697).



5. Install the gauge bar (1) onto the case mounting surface.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Install bolts to J 44472 and tighten securely to prevent tool deflection during end play measurement.

6. Install J 44472  (2) onto the transmission.

Tighten
Tighten J 44472 to remove end play. Hand tighten only.




7. Measure the distance from the case mounting surface, bottom of the gauge bar (1) to the top of the final drive sun gear (697). This measurement is dimension A, refer to Transfer Case Selective Washer Specifications .
8. Remove the gauge bar (1) and J 44472  (2).



9. Install the gauge bar onto the carrier.
10. Measure the distance from the bottom of the gauge bar to the transfer case. This measurement is Dimension B1.



11. Measure the distance from the bottom of the gauge bar to the thrust bearing (1). This measurement is Dimension B2.
12. Subtract Dimension B2 from Dimension B1. This Dimension is B.
13. Subtract final Dimension B from Dimension A. Use this final Dimension to determine the correct selective washer color, by choosing the range between the upper and lower values in the chart. Refer to Transfer Case Selective Washer Specifications .
14. Remove the gauge bar from the transfer case.



15. Remove the final drive sun gear (697).



16. Refer to Transfer Case Selective Washer Specifications .

Install the selective washer (902).





Important: The counterbore on the final drive sun gear installs towards the parking gear.

17. Install the final drive sun gear (697).

Transmission to Transfer Case End Play Check F4WD Only

Important: Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. Refer to Internal Components Cleaning and Inspection .

1. Position the transaxle so that the case side cover is facing down.
2. Install the final drive sun gear shaft (689).




Notice: The park gear thrust bearing (695) must be retained in the park gear (696) when installing the transfer case to the transmission, or damage may occur.

3. Use J 36850 or equivalent in order to retain the parking gear thrust bearing (695) to the parking gear (696).

Install the parking gear thrust bearing (695) and the parking gear (696).





Important: The counterbore on the final drive sun gear installs towards the parking gear.

4. Install the final drive sun gear (697).



5. Install the gauge bar (1) onto the case mounting surface.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Install bolts to J 44472 and tighten securely to prevent tool deflection during end play measurement.

6. Install J 44472  (2) onto the transmission.

Tighten
Tighten J 44472 to remove end play. Hand tighten only.




7. Measure the distance from the case mounting surface, bottom of the gauge bar (1) to the top of the final drive sun gear (697). This measurement is dimension A, refer to Transfer Case Selective Washer Specifications .
8. Remove the gauge bar (1) and J 44472  (2).



9. Install the gauge bar onto the carrier.
10. Measure the distance from the bottom of the gauge bar to the transfer case. This measurement is Dimension B1.



11. Measure the distance from the bottom of the gauge bar to the thrust bearing (1). This measurement is Dimension B2.
12. Subtract Dimension B2 from Dimension B1. This Dimension is B. Refer to Transfer Case Selective Washer Specifications .
13. Remove the gauge bar from the transfer case.



14. Remove the final drive sun gear (697).



15. Refer to Transfer Case Selective Washer Specifications .

Install the selective washer (902).





Important: The counterbore on the final drive sun gear installs towards the parking gear.

16. Install the final drive sun gear (697).