Transfer Case: Inspection

Replace any worn or damaged part. Ensure detent ball spring meets standard of .768" (19.50 mm) and service limit of .709" (18.00 mm). Replace all seals and "O" rings. Measure shift fork-to-sleeve clearance. See Fig 1. Clearance should be .039" (1.0 mm). If clearance is not within specifications, replace shift fork and sleeve as necessary.

Fig 1: Measuring Shift Fork Clearance

Courtesy of SUZUKI OF AMERICA CORP.