Two_Four Wheel Drive Shift Components Cleaning and Inspection (1)

Two/Four Wheel Drive Shift Components Cleaning and Inspection

Two_Four Wheel Drive Shift Components Cleaning and Inspection (1) — figure 1

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 all components in cleaning solvent and air dry, except the clutch plates.
3. Inspect the transfer case control actuator thrust bearing (1). Replace the bearing if roughness, brinelling, or pitting is detected.
4. Transfer case control actuator lever thrust bearing surface (2) 4.1. Inspect for pitting, excessive wear, or damage. 4.2. Refer to: New Product Information for changes.
5. Inspect the transfer case control actuator lever bearing surface (3) for pitting, excessive wear, or damage.
6. Inspect the transfer case control lever arm (4) for excessive wear or damage.
7. Inspect the transfer case control actuator lever ball ramps (5) for excessive wear or damage.
8. Inspect the transfer case control actuator lever bearing (6). Replace the bearing if roughness, brinelling, or pitting is detected.
9. Inspect the transfer case control actuator lever balls (7) Replace the bearings if roughness or pitting is detected.
10. Inspect the transfer case control actuator lever ball ramps (8) for pitting, excessive wear, or damage.
11. Inspect the transfer case control actuator lever bearing (9). Replace the control actuator lever assembly if roughness, brinelling, or pitting is detected.
12. Inspect the transfer case control actuator lever bearing surface (10) for pitting, excessive wear, or damage.
13. Inspect the transfer case control actuator thrust bearing (11). Replace the bearing if roughness, brinelling, or pitting is detected.
14. Inspect the transfer case control actuator lever washer (12) for pitting, excessive wear, or damage.
15. Inspect the transfer case four wheel drive clutch pressure (apply) plate washer surface (13) for pitting, excessive wear, or damage.
16. Inspect the transfer case four wheel drive clutch pressure (apply) plate surface (14) for excessive wear, cracks, or damage.
17. Inspect the transfer case four wheel drive clutch pressure plate springs (15) for cracks.
18. Inspect the transfer case four wheel drive clutch pressure (friction) plates (16) for worn, grooved, burnt, or flaking friction material, or warped friction plates.
19. Inspect the transfer case four wheel drive clutch pressure (steel) plates (17) for worn or warped steel plates.
20. Inspect the transfer case four wheel drive clutch hub bearing surface (18) for pitting, excessive wear, or damage.
21. Inspect the transfer case four wheel drive clutch hub teeth (19) for excessive wear or damage. Excessive wear can be identified by steps in the teeth.
22. Inspect the transfer case four wheel drive clutch hub friction plate surface (20) for excessive wear, cracks, or damage.
23. Inspect the transfer case front output shaft drive sprocket engagement teeth (21) splines for excessive looseness on the rear output shaft.
24. Inspect the transfer case four wheel drive clutch housing teeth (22) for excessive wear or damage. Excessive wear can be identified by steps in the teeth.
25. Inspect the transfer case four wheel drive clutch hub splines (23) for excessive looseness on the rear output shaft.
26. Inspect the transfer case two/four wheel drive actuator cam (24) lobes for wear or roughness.
27. Inspect the transfer case two/four wheel drive actuator cam spacer (25) for wear or roughness.