Transfer Case Rear Half Cleaning and Inspection (1)

Transfer Case Rear Half Cleaning and Inspection

Transfer Case Rear Half Cleaning and Inspection (1) — figure 1

Caution

Refer to Machined Surface Damage Caution.

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.
4. Inspect the transfer case rear case half assembly (1) for cracks, broken areas, or other damage. The component must be replaced if damage is found.
5. Inspect the transfer case access hole plug (2). Replace the rear case half assembly if the speed sensor threads are damaged.
6. Inspect the transfer case rear output shaft rear bearing outer retaining ring groove (3). Replace the rear case half assembly if the groove is worn.
7. Inspect the transfer case rear output shaft rear bearing bore (4). Replace the rear case half assembly if a bearing has spun or if cracks are detected.
8. Inspect the transfer case four wheel drive actuator lever shaft bearing bore (5). Replace the front case half assembly if a bearing has spun or if cracks are detected.
9. Inspect the case sealing surface (6).

Note

Repair small scratches or nicks with a soft stone.

10. Inspect the transfer case four wheel drive actuator lever shaft bearing assembly (7). Replace the bearing if roughness, brinelling, or pitting is detected. Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Replacement - Rear
11. Inspect the transfer case front output shaft rear bearing bore (8).

Note

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

12. Inspect the transfer case locating pin holes (9).

Note

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

13. Inspect the transfer case rear output shaft bushing (10). 13.1. Replace the bushing if it is damaged or worn. Transfer Case Disassemble and Transfer Case Assemble 13.2. If the bushing is removed, inspect the bushing bore for signs of spinning. Replace the rear case half assembly if the bushing has spun.