Preliminary Procedures

1. Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated.
2. Clean all components in cleaning solvent and air dry.

1

Transfer Case Rear Output Shaft Splines

Tip
Witness marks at the location of the yoke are normal.

2

Transfer Case Front Output Shaft Drive Sprocket Bearing Surface

Tip
Inspect for scoring, brinelling, pitting, or excessive wear.

3

Front/Rear Drive Differential Carrier Assembly Engagement Splines

Tip
Witness marks at the location of the splines are normal.

4

Transfer Case Input Gear Thrust Bearing Surface

Tip
Inspect for scoring, brinelling, pitting, or excessive wear.

5

Oil Galleries

Tip
Compressed air may be necessary to clean the oil galleries.