Notice: Refer to Machined Surface Damage Notice in the Preface section.

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 the front case half in cleaning solvent and air dry.
3. Remove any sealant from the sealing surface.

1

Transfer Case Front Half Assembly

Tip
Inspect for cracks, broken areas, or other damage. The component must be replaced if damage is found.

2

Transfer Case Adapter Stud (Qty: 5)

Tip
Replace any damaged studs.

3

Case Sealing Surface

Tip
Repair small scratches or nicks with a soft stone.

4

Transfer Case Front Input Double Row Ball Bearing Bore

Tip
Replace the front half case assembly if a bearing has spun or if cracks are detected.

5

Transfer Case Front Output Shaft Front Bearing Bore

Tip
Replace the front half case assembly if a bearing has spun or if cracks are detected.

6

Transfer Case Thread Bolt Holes

Tip
Repair any damaged threads.

7

Transfer Case Locating Pin Holes

Tip
Replace the front half case assembly if the locating pin holes are out of round or damaged.

8

Transfer Case Front Output Shaft Front Bearing

Tip
Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Front Output Shaft Bearing and Front Input Bearing Replacement .

9

Transfer Case Front Input Double Row Ball Bearing

Tip
Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Front Output Shaft Bearing and Front Input Bearing Replacement .