DCS/DCD Main shaft issue The most common reason for replacing the transfer case shaft in DCS (as well as DCD) transfer cases is damage to the external splines on the side of the connection with the gearbox. At first, this manifests itself as excess play when starting and stopping, but as this problem progresses, it can result in the car's complete inability to move under its own power. In Figure 1, we showed what damaged main shaft splines look like. Important note: When replacing the transfer case shaft, you should also replace the mating cup on the gearbox side —...
ATC300/ATC400/ATC500/ATC700 clutch common issue The ATC300/ATC400/ATC500/ATC700 transfer case clutches are structurally similar and, therefore, have common weak points. Oddly enough, in most cases, their failure is caused not by friction plates but by the wear of the clutche's metal parts. Having extensive experience in their repair, we were the first on the market to offer the optimal kits for their professional repair. Illustration 1 shows a typical case of worn parts on an ATC400(ATC300/ATC500/ATC700) transfer case. The arrows show the grooves on parts 75 (Actuator ring/Lever/Grip) and 76 (Piston) and the needle bearing that caused the formation of these grooves....
When is it appropriate to use such a kit? The photo below shows the contents of one of the disassembled ATC400 transfer cases done about 200`000km. A fairly common situation is that a crumbling bearing damages the lever and piston. Metal dust has embedded itself in the friction discs. Metal shavings also damaged the oil pump and drum. The condition of ball bearings is challenging to assess but can also be questioned. The use of a complete overhaul kit in such a situation is a guarantee of the quality of the repair performed.
