Callout
| Component Name
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Caution: Refer to Machined Surface Damage Caution in the Preface section.
Preliminary Procedure
| • | 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. |
| • | Clean the rear case half in cleaning solvent and air dry. |
| • | Remove any sealant from the sealing surface. |
|
1
| Transfer Case Rear Case Half Assembly
Tip
Inspect for cracks, broken areas, or other damage. The component must be replaced if damage is found. |
2
| Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring Groove
Tip
Replace the rear case half assembly if the groove is worn. |
3
| Vehicle Speed Sensor Threads
Tip
Replace the rear case half assembly if the speed sensor threads are damaged. |
4
| Transfer Case Rear Output Shaft Rear Bearing Bore
Tip
Replace the rear case half assembly if a bearing has spun or if cracks are detected. |
5
| Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Bore
Tip
Replace the front case half assembly if a bearing has spun or if cracks are detected. |
6
| Case Sealing Surface
Tip
Repair small scratches or nicks with a soft stone. |
7
| Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly
Tip
Replace the bearing if roughness, brinelling, or pitting is detected. Refer to
Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Replacement - Rear. |
8
| Transfer Case Front Output Shaft Rear Bearing Bore
Tip
Replace the rear case half assembly if a bearing has spun or if cracks are detected. |
9
| Transfer Case Locating Pin Holes
Tip
Replace the rear case half assembly if the locating pin holes are out of round or damaged. |
10
| Transfer Case Rear Output Shaft Bushing
Tip
| • | If the bushing is removed, inspect the bushing bore for signs of spinning. Replace the rear case half assembly if the bushing has spun. |
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