Front Case Half
- Clean the front case half in cleaning solvent and air dry.
Notice: Do not nick, scratch or damage the sealing surface. The
sealing surface is a machined surface. Damage to the machined surface can
cause leakage.
- Remove the sealer from the case sealing surfaces.
- Inspect the front output shaft front bearing (4) for the following conditions:
- Replace the front output shaft front bearing if any of the above conditions are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the case for spun bearings.
- Replace the case if a bearing has spun.
- Inspect the case for being broken or cracked.
- Replace the case if it is broken or cracked.
- Inspect the sealing surfaces (1) for damage.
- Repair small scratches or nicks with a soft stone.
- Inspect the front case to transmission case mounting surface for damage.
- Inspect the case threaded bolt holes (3) for damage.
- Repair any damaged threads.
- Inspect the transmission to transfer case studs (2) for damage.
- Replace any damaged studs.
Rear Case Half
- Clean the rear case half in cleaning solvent and air dry.
Notice: Do not nick, scratch or damage the sealing surface. The
sealing surface is a machined surface. Damage to the machined surface can
cause leakage.
- Remove the sealer from the case sealing surfaces.
- Inspect the front output shaft rear bearing (5) for the following conditions:
- Replace the front output shaft rear bearing if any of the above conditions are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the rear output shaft bearing (6) for the following conditions:
- Replace the rear output shaft bearing if any of the above conditions are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the case for spun bearings.
- Replace the case if a bearing has spun.
- Inspect the control actuator lever shaft bearing and seal (3) for the following conditions:
- Replace the control actuator lever shaft seal and bearing if any of the above conditions are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the case for being broken or cracked.
- Replace the case if it is broken or cracked.
- Inspect the sealing surfaces (1) for damage.
- Repair small scratches or nicks with a soft stone.
- Inspect the case threaded bolt holes for damage.
- Repair any damaged threads.
- Inspect the dowel pins (4) for being loose or missing.
- Repair or replace any damaged dowel pins.
- Inspect the oil pump bushing bore (7) for scoring or damage.
- Replace the case if the oil pump bushing bore is damaged.
- Inspect the clutch lever studs (2) for wear.
- Replace the case if the clutch lever studs are worn.
Oil Pump Suction Pipe Assembly
- Remove the oil pump suction pipe and the oil pump suction hose from the oil pump
screen.
- Clean the pipe, hose, and screen in cleaning solvent and air dry.
- If the screen is embedded with debris, replace the screen.
- Inspect the hose for cracking or tears.
- Replace the hose if faulty.
Rear Extension
- Clean the rear extension in cleaning solvent and air dry.
Notice: Do not nick, scratch or damage the sealing surface. The
sealing surface is a machined surface. Damage to the machined surface can
cause leakage.
- Remove the sealer from the extension sealing surfaces (2).
- Inspect the extension for being broken or cracked.
- Replace the extension if it is broken or cracked.
- Inspect the sealing surfaces for damage.
- Repair small scratches or nicks with a soft stone.
- Inspect the dowel pins (3) for being loose or missing.
- Repair or replace a damaged dowel pin.
- Inspect the rear extension bushing (1) for scoring and excessive wear.
- Replace the rear extension bushing if damaged or worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
Rear Output Shaft
- Clean the rear output shaft in cleaning solvent.
- Clean the rear output shaft oil galleries (1) and air dry.
Important: Do not attempt to smooth any roughness in the bearing journals or seal surfaces.
- Inspect the input gear thrust bearing surface (2) and the clutch housing bearing surface (3) for the following conditions:
- Inspect the rear output shaft splines (4) for damage or excessive wear. Witness marks at the location of the gears is normal.
- Replace the rear output shaft if any of the above conditions are found.
Clutch Components
- Do not clean the inner clutch discs (1) and outer clutch discs (2) in cleaning solvent.
- Inspect the clutch discs for the following conditions:
| • | Grooved or scored friction material |
- Replace the clutch discs if any of the above conditions are found.
- Clean the clutch inner plate (1)
and the clutch pressure plate bearing (2) in cleaning solvent and air dry.
- Inspect the pressure plate bearing for roughness and smooth movement.
- Replace the pressure plate bearing if damaged or worn.
- Inspect the clutch inner plate inner bushing for wear or damage.
- Inspect the clutch inner plate for wear.
- Replace the clutch inner plate if any of the above conditions are found.
- Clean the clutch housing, with the bearing, in cleaning solvent.
- Air dry and ensure all solvent is removed from the bearing.
- Inspect the bearing for wear or damage.
- Inspect the clutch housing disc teeth for excessive wear. Excessive wear can be identified by the steps in the teeth, which prevents the clutch disc from moving freely.
- Replace the clutch housing if the bearing is faulty or if the clutch disc teeth are worn. The bearing is not serviced separately.
- Clean the clutch hub in cleaning solvent and air dry.
- Inspect the inner splines of the clutch hub for wear or damage.
- Inspect the clutch inner hub on the rear output shaft for excessive wear on the splines.
- Inspect the clutch hub teeth for excessive wear. Excessive wear can be identified by the steps in the teeth, which prevents the clutch disc from moving freely.
- Replace the clutch hub if any of the above conditions are found.
- Clean the clutch lever in cleaning solvent and air dry.
- Inspect the clutch lever roller (1) for the following conditions:
- Inspect the clutch lever for worn wear pads (2).
- Inspect the clutch lever for wear at the pivot pin sockets (3).
- Replace the clutch lever if the above conditions are found.
- Clean the control actuator lever shaft in cleaning solvent
and air dry.
- Inspect the roller (1) on the control actuator lever shaft for the following conditions:
- Inspect the bearing (2) and the seal surface on the control actuator lever shaft for the following conditions:
- Replace the control actuator lever shaft if any of the above conditions are found.
Drive Chain and Sprockets
- Clean the drive chain (1), drive
sprocket (3), and driven sprocket (2) in cleaning solvent and air dry.
- Inspect the drive chain (1) for the following conditions:
| • | Debris embedded in the links |
- Replace the chain if any of the above conditions are found.
- Inspect the driven sprocket (2) and the drive sprocket (3) for the following conditions:
| • | Excessive worn gear surfaces, slight wear marks are normal |
| • | Debris embedded in the root of the teeth |
- Replace the sprocket if any of the above conditions are found. The chain and sprockets may be replaced separately.
Front Output Shaft
- Clean the front output shaft in cleaning solvent and air dry.
- Inspect the teeth on the speed sensor reluctor wheel (3) for damage.
- Replace the speed sensor reluctor wheel if damaged.
- Inspect the front output shaft seal surface (2) for wear or damage.
- Inspect the front output shaft splines (1) for damage.
- Replace the front output shaft if damaged.
Input Gear
- Clean the input gear, with thrust bearing, in cleaning solvent.
- Air dry, and ensure all solvent is removed from the thrust bearing.
- Inspect the thrust bearing (1) for the following conditions:
- Replace the input gear thrust bearing if any of the above conditions are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the internal splines (2) for:
- Replace the input gear if any of the above conditions are found.
