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Pinpoint Test M: Transfer Case Vibration

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. M1 INSPECT THE TRANSFER CASE 
      WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
    • Inspect the transfer case for loose or missing mounting bolts. Check for fluid seepage between the transfer case and the transmission.
    • Are the mounting bolts missing or loose? 
    1. Yes  : TIGHTEN to specifications or INSTALL new bolts as necessary. TEST the system for normal operation.
    2. No  : GO to M2.
  2. M2 INSPECT THE REAR DRIVESHAFT 
      NOTE: Verify that the driveshaft and pinion flange index marks are aligned.
    • Inspect the driveshaft for missing weights, damage or undercoating.
    • Inspect the U-joints for freedom of movement.
    • Check driveshaft runout and, if necessary, check the pinion flange runout. Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
    • Is the driveshaft or U-joints worn or damaged or misaligned? 
    1. Yes  : REPAIR or INSTALL a new driveshaft as necessary. TEST the system for normal operation.
    2. No  : GO to M3.
  3. M3 CHECK THE DRIVELINE ANGLES 
    1. Yes  : REPAIR as necessary. TEST the system for normal operation.
    2. No  : GO to M4.
  4. M4 INSPECT THE FRONT DRIVESHAFT 
      NOTE: Verify that the driveshaft and pinion flange index marks are aligned.
    • Inspect the front driveshaft for missing weights, damage or undercoating.
    • Inspect the U -joints and slip yoke for freedom of movement.
    • Check driveshaft runout and, if necessary, check the pinion flange runout.
    • Is the driveshaft or U-joints worn or damaged? 
    1. Yes  : REPAIR or INSTALL a new driveshaft as necessary. TEST the system for normal operation.
    2. No  : GO to M5.
  5. M5 ROAD TEST WITH THE FRONT DRIVESHAFT ONLY 
      NOTE: Index mark the driveshaft to the pinion flange and to the output shaft before removal.
    • Remove the rear driveshaft.
    • Plug the transfer case with an output shaft seal plug.
      • NOTE: Shift the transfer case into 4WD high so the vehicle is driven by the front driveshaft only.
    • Test drive the vehicle.
    • Is the vibration gone? 
    1. Yes  : INSTALL and BALANCE the rear driveshaft. TEST the system for normal operation.
    2. No  : GO to M6.
  6. M6 ROAD TEST WITH THE REAR DRIVESHAFT ONLY 
      NOTE: Index mark the front driveshaft to the pinion flange.
    • Remove the front driveshaft.
    • Test drive the vehicle.
    • Is the vibration gone? 
    1. Yes  : INSTALL and BALANCE the front driveshaft. TEST the system for normal operation.
    2. No  : GO to M7.
  7. M7 TRANSFER CASE TAIL SHAFT INSPECTION 
    • Inspect the splines of the output shaft for wear or damage.
    • Inspect the splines of the driveshaft slip yoke for wear or damage.
    • Are the splines worn or damaged? 
    1. Yes  : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
    2. No  : The transfer case is OK. CONDUCT a diagnosis on other suspect systems.
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