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

1

Transfer Case Rear Case Half

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

2

Transfer Case Locating Pin Holes

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

3

Transfer Case Rear Case Half Sealing Surface

Tip
Repair small scratches or nicks with a soft stone.

4

Transfer Case Rear Output Shaft Bearing Assembly Bore

Tip
Replace the rear case half if the bearing has spun or if cracks are detected.

5

Transfer Case Front Output Shaft Rear Bearing Bore

Tip
Replace the rear case half if the bearing has spun or if cracks are detected.

6

Transfer Case Oil Drain Plug Threads

Tip
Repair any damaged threads.

7

Transfer Case Front Output Shaft Rear Bearing

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

8

Transfer Case Oil Fill Plug Threads

Tip
Repair any damaged threads.

9

Transfer Case Rear Output Shaft Bearing Assembly

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

10

Transfer Case Locating Pins (Qty: 2)

Tip
Repair or replace loose, missing, or damaged locating pins.

11

Transfer Case Oil Pump Cover Sealing Surface

Tip
Repair small scratches or nicks with a soft stone.

12

Transfer Case Oil Pump Drive and Driven Gear Bore

Tip
Replace the rear half case if the bore is damaged.