Repair Manual
MAN-00
190
THAR
CRDe
BS-IV
MAY
2012
/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
Trouble Shooting
Inspection and Verification
1. Verify the customer‘s concern.
2. Visually inspect the transfer case for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding next step.
4. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart.
Mechanical
•Check for any oil leakage in the transfer case.
•Check the yoke, flange, drive gear and shift motor for any damage.
•Check for loose mounting bolts.
Electrical
•Check for any damage and continui
ty in the transfer case wiring harness.
•Check for malfunction of the transfer case module and 2W/4W change switches.
Troubleshooting Chart
Symptom
Possible Causes
Remedy
No front wheel drive when
shifted to 4WD.
1.
Broken drive chain link‐age.
2.
Shift motor faulty
3.
Selection switch faulty
4. TCCU faulty
5. Faulty wiring harness
1. Check the drive chain and
re‐place it if necessary.
2. Check the motor, replace if
necessary.
3. Check the selection switch,
re‐place if necessary.
4. Check and replace the TCCU.
5. Check the wiring harness and
rectify the problem.
Noise during 4WD operation.
(Make sure that noise comes
from the transfer case and not
from clutch, transmission, drive
shaft, au‐tomatic locking hubs
or other components.)
1. Transfer case oil level is too
low.
2. Loose bolts or mounting parts
of transfer case.
3. Noisy or worn transfer case
bearings.
4. Worn or damaged gears.
5. Worn or damaged sprockets.
1. Drain old oil and fill the
transfer case with specified oil.
2. Tighten the bolts and nuts to
the specified torque.
3. Disassemble the transfer case
parts, and check the bearings
for wear or damage, and
replace it if necessary.
4. Check for wear and damage
of the gear including
speedometer gear and replace
necessary parts.
5. Disassemble and check the
sprockets for wear and damage,
replace if it is worn‐out.
Page 211
