Symptom Chart

SYMPTOM CHART

Condition	Possible Sources	Action
The transfer case makes noise	Tire inflation pressure. Tire and wheel size.	MAKE SURE that all the tires and wheels are the same size and that the inflation pressures are correct.
	Tire tread wear.	CHECK the tire tread wear to see if there is more than 0.15 mm (0.06 in) difference in tread wear between the front and rear tires. INTERCHANGE one front wheel and one rear wheel. Road test again.
	Internal components.	OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . If there is noise in all gears, DISASSEMBLE the transfer case. REFER to TRANSFER CASE . CHECK the input gear and intermediate and front output shaft gear for damage. INSTALL new parts as necessary.
	Lubricant level.	FILL with automatic transmission fluid (ATF). REFER to TRANSFER CASE DRAINING AND FILLING .
Wheel/tire bounce, vehicle skip	Internal components.	OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to AUTOMATIC TRANSAXLE/TRANSMISSION . If there is noise in all gears, DISASSEMBLE the transfer case. REFER to TRANSFER CASE . CHECK the input gear and intermediate and front output shaft gear for damage. INSTALL new parts as necessary.
Wheel/tire bounce, vehicle skip	Tire tread wear.	MAKE SURE that all tires and wheels are the same size and that inflation pressures are correct. REFER to SUSPENSION SYSTEM .
Leaking automatic transmission fluid (ATF) from the vent	Transfer case.	DRAIN the fluid to the correct level. REFER to TRANSFER CASE DRAINING AND FILLING .
Leaking automatic transmission fluid (ATF) from the vent	Vent tube.	REPAIR or INSTALL a new vent tube. REFER to TRANSFER CASE .
Leaking automatic transmission fluid (ATF) from transfer case housing	Transfer case housing bolts.	TIGHTEN the bolts to specification. REFER to SPECIFICATIONS .
	Sealant.	RESEAL the transfer case with black non-acid cure silicone rubber. REFER to TRANSFER CASE .
	Fluid.	DRAIN fluid and FILL with ATF. REFER to TRANSFER CASE DRAINING AND FILLING .
	Transfer case gasket.	INSTALL a new transfer case gasket. REFER to TRANSFER CASE .
Leaking automatic transmission fluid (ATF) from the output shaft seals	The vent is plugged.	REPAIR the plugged vent.
	Output shaft seals.	INSTALL new output shaft seals. REFER to TRANSFER CASE .
The front axle does not engage correctly	Front axle.	REFER to DRIVELINE SYSTEM .
	Transfer case clutch.	Go To PINPOINT TEST B .
	Internal components.	DISASSEMBLE the transfer case. REFER to TRANSFER CASE . CHECK the input gear, and the intermediate and front output shaft for damage. INSTALL new parts as necessary.
No communication with the 4-wheel drive (4WD) control module	Diagnostic tool. Battery junction box (BJB) fuse 18 (20A). 4WD control module. 4WD control module connectors. Circuitry.	Go To PINPOINT TEST A .