SkyTrak 3606 Service Manual - Manual (Page 133)

Transfer Case and Drive Shafts
6-9
6.5 TROUBLESHOOTING This section provides an easy reference guide covering
the most common problems that occur during operation
of the transfer case.
Transfer Case and Drive Shaft Troubleshooting
Problem Cause Remedy
1. Gear teeth worn or grooved. 1. Insufficient lubrication.
2. Contaminated lubricant.
• Replace gear.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
2. Gear teeth overheated
(check color of gear teeth).
1. Prolonged operation at high
temperatures.
2. Incorrect lubricant.
3. Low oil level.
4. Lubricant contaminated.
• Replace gear.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
3. Gear teeth pitted. 1. Intensive use.
2. Insufficient lubrication.
3. Lubricant contaminated.
• Replace gear.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
4. Transfer box housing bent
or cracked.
1. Insufficient lubrication.
2. Lubricant contaminated.
3. Intensive use.
4. Normal wear.
5. Inadequate bearing preload.
• Replace bearings.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
• Correct preload.
5. Leaks from oil seal ring. 1. Prolonged operation at high
temperatures.
2. Seals fitted incorrectly.
3. Seal lip damaged.
4. Lubricant contaminated.
• Replace seal, and parent surface,
if damaged.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
6. Worn shaft splines. 1. Intensive use.
2. Loose nut.
• Replace flanges.
• Check shaft splines for excessive
wear; replace as required.
7. Gear tooth fatigue fracture
(check whether the fracture
line is well-defined).
1. Intensive use.
2. Continuous overloading.
• Replace gear.
• DO NOT overload.
8. Worn inside cup or worn
tapered roller bearing.
1. Intensive use.
2. Excessive gear end float.
3. Insufficient lubrication.
4. Lubricant contaminated.
• Replace bearing.
• Check end float.
• Use correct lubricant. Fill to correct
level and change at recommended
intervals.
9. Noise when coasting; even
slight transfer case noise
can be heard when vehicle
is coasting.
1. Worn splines on input flange,
gears or shafts.
• Adjust or replace (see
Troubleshooting step 10).
Model 3606 • Origin 10/99