GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 1998 🢒 SL1/SC1/SW1 🢒 Driveline/Axle 🢒 Transfer Case - BW 4401 (Two Speed Manual) 🢒 Transfer Case Cleaning and Inspection
  1. Clean the following components:
    2. 1.1. The bearings
    1.2. The shafts
    1.3. The sprockets
    1.4. The chain
    1.5. The oil feed ports and channels.

    Apply compressed air to each oil feed port and each channel in both case halves in order to remove any obstructions or cleaning solvent residue.

    1.6. All mating surfaces.
  2. Inspect the bearings and the thrust washers for the following conditions:
    3. • Wear
    • Spalling
    • Brinelling
    • Corrosion
  3. Inspect the gear teeth for the following conditions:
    4. • Excessive wear or damage
    • Spalling
    • Cracks
    • Corrosion
  4. Inspect the gear splines for the following conditions:
    5. • Excessive wear
    • Spalling
    • Cracks
    • Twist
    • Corrosion
  5. Inspect the shaft spines for the following conditions:
    6. • Excessive wear
    • Spalling
    • Cracks
    • Distortion
    • Corrosion
  6. Inspect the retainer rings for the following conditions:
    7. • Excessive wear
    • Distortion
    • Damage
  7. Inspect the case halves for the following conditions:
    8. • Damaged or warped mating surfaces
    • Cracks
    • Porosity
    • Damaged thread holes
  8. Inspect the following components for excessive wear:
    9. • The input gear
    • The planetary carrier