Transfer Case Identification Guide

1 Transfer case Identification Guide S. tandard transmissions, which dominance of SUV's and the great once were found in 100% of all expansion of the light truck market, the cars and trucks produced, now greatest growth in the gearboxes is in occupy 18-20% of the overall US mar- Transfer cases. It is easy to predict the by Mike Weinberg, President, ket. Transfer cases, which once occu- continuation of this trend as manufac- Rockland Standard Gear Inc. pied only a fraction of the market, have turers create new technology to make grown exponentially. Fueled by the more passenger cars all-wheel-drive. Figure 1 Figure 2. 26 GEARS March 2002.

2 These cross over vehicles will contin- of offshore units. Transfer case that was built by New ue to grow as the public demands better The two major Transfer case manu- Process Gear will be included in the handling and traction year round. facturers are Borg Warner Torque New Venture Transfer case line for pur- In the 60s there was only a handful Transfer Systems, and the New Venture poses of this article. of Transfer cases used by the American Gear Co. New Venture Gear was a joint One of the greatest problems fac- carmakers. Typically of cast iron con- venture between Daimler Chrysler ing the transmission rebuilder and parts struction and heavy, they were bypassed Corporation and GM.

3 This deal was suppliers in the last decade or so is the after the energy crisis of the 70s made recently dissolved, but it consisted of tremendous proliferation of new units. fuel economy and weight savings a high the New Process Gear Division of The Transfer case is no different, with a priority. Today, there are over 40 Chrysler joining with the Muncie number of new units appearing annual- different models of Transfer cases of Division of GM to produce manual ly. Adding to the confusion is the fact American manufacture plus a number transmissions and Transfer cases. Any that a great number of Transfer case Input Splines Input spline count: The spline count on the input is Input length measured from the input seal with the unit critical because it must match up to the splines on the assembled.

4 There are many different input dimensions to output Shaft it will be attached to. Figure 3 fit the different transmissions and extension Housings. Figure 4. What Makes So Special? 604 Transfer case Assembly: Experience The Difference! 604 Transfer case assembly comes with: 1. New Ring and Pinion 2. New Bearings and Races 3. New Seals and O-Rings 4. New Plastic Oil Trough 5. Inspected and assembled with care 1-800-776-4433. Fax: 1-856-222-4169. GEARS March 2002 27. Transfer case Identification Guide Bolt On Output Slip On Splines Output shaft spline count The output shaft must match the rear drive shaft. Type of yoke on the output shaft (slip yoke, bolt on yoke).

5 Figure 5 Figure 6-7. Round Front of Vehicle 241 Left Hand Flange U-Joint Drive Right or left hand drive. Determine which side of the Type of flange on front and rear output shafts (round flange or U Joint). vehicle the front output shaft is situated on. Some models of This covers a broad area. We now have round flanges, U joint yokes, CV Transfer cases come in right and left hand drive versions for Joints, and male and female splines to contend with. the same vehicle line. (Figures 10, 11). Figure 8-9 Figure 10. 241 Right WITH WITHOUT. Hand Drive Speedometer Front of Vehicle Opening With or without speedometer drive. Transfer cases of the same model come with and without speedometer drives depending on year or manufacture.

6 Figure 11 Figure 12-13. models cross over multiple car lines, to a GM powertrain, but most shops the correct information when ordering and while the basic design is the same, don't realize that there are 12 different parts or a unit. Again, for reasons there are numerous variations that are variations of the 231 found in Jeeps. unknown, a great many shops resist model specific. For reasons unknown Add 6 more for GM and 11 models for answering the questions that the parts many people in the repair industry think Dodge and we have 29 models of the supplier needs to make this one-stop that one size fits all. For example, the 231 Transfer case that can find their way shopping.

7 NV231 Transfer case is found in Dodge, into your shop. The intent of this article Jeep, and GM vehicles. It is easy to is to explain the differences between Tag and Vehicle Identification realize that a Jeep 231 will not bolt up these variations, so that you can obtain It is absolutely necessary to note as 28 GEARS March 2002. Transfer case Identification Guide Electric Vacuum Switches can be 2,3 or 4 wire or 2,3,4,5 vacuum ports. Length of Switch threads Type and location of switches. Many Transfer cases use electric or vacuum switches to indicate shifter position to operate vacuum diaphragms or solenoids to shift the unit or engage and disengage the front differential.

8 Knowing the type and location of switch is mission critical. Figure 14a-e Manual Shift Electric Shift Manual or electric shift. Late model Transfer cases are built in both varieties. Note the manual lever position Shift Motor and wiring connectors to make sure they match. Figure 15-16. Power Take offs. A Number of heavy-duty Transfer cases are equipped with a PTO. You can always use a PTO equipped unit to replace one without, but if a unit is equipped with a PTO, you don't want to deny the option to your customer. Figure 17. Number and location of speed sensors. Some Transfer cases are equipped with speed sensors and speedometer drives while others use speed sensors to read vehicle speed.

9 A mismatch means more work and a job delayed. Figure 18. much information as possible about the ID tag. Typical ID tags are shown here vehicle specs. On late model units you vehicle. Year, production date, engine (Figures 1 & 2) with an explanation of will find barcode decals on the cases size and type, and model of transmis- what the information means. Record with OEM part numbers attached. sion are all vital pieces of information. this information on your work order Next we must look at the Transfer case along with the previously gathered 30 GEARS March 2002. Transfer case Identification Guide Live Shaft Extension Housing Live shaft or extension housing.

10 Many late model New Venture Transfer cases have eliminated the extension housing and have gone to a live rear output shaft. Figure 19-20. Manual Hubs Automatic Hubs NP 242. Shifter pattern on vehicle shift lever. Manual or Automatic Front Axle locking hubs. Always note the shift pattern inside the Vehicles equipped with manual locking hubs usually have no vehicle. The same model Transfer case synchronization in the Transfer case because it is impossible to shift may be produced with different shift on the fly. Mistakes here create problems with swapping units. patterns. Figure 21-22 Figure 23. Regular Allen Regular or Allen head bolts on the front bearing retainer.