Two_Four Wheel Drive Shift Components Cleaning and Inspection

Two/Four Wheel Drive Shift Components Cleaning and Inspection

Two_Four Wheel Drive Shift Components Cleaning and Inspection — 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. Transfer Case Control Actuator Thrust Bearing (1) » Replace the bearing if roughness, brinelling, or pitting is detected.
4. Inspect the transfer case control actuator thrust bearing surface (2) for pitting, excessive wear, or damage.
5. Inspect the transfer case control actuator lever bearing surface (3) for pitting, excessive wear, or damage.
6. Transfer Case Control Lever Arm (4) » Inspect for excessive wear or damage.
7. Inspect the transfer case control actuator lever ball ramps (5) for pitting, excessive wear, or damage.
8. Transfer Case Control Actuator Lever Bearing (6) » Replace the bearing if roughness, brinelling, or pitting is detected.
9. Transfer Case Control Actuator Lever Ball (7) » Replace the bearing if roughness, brinelling, or pitting is detected.
10. Transfer Case Control Actuator Lever Ball Ramp (8) » Inspect for excessive wear or damage.
11. Inspect 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 excessive wear or damage.
13. Transfer Case Control Actuator Thrust Bearing (11) » Inspect for excessive wear or damage.
14. Transfer Case Control Actuator Lever Washer (12) » Inspect for excessive wear or damage.
15. Inspect the transfer case four wheel drive clutch pressure plate – apply washer surface (13) for excessive wear or damage.
16. Inspect transfer case four wheel drive clutch pressure plate – apply (14) Inspect for excessive wear, cracks, or damage.
17. Inspect the transfer case four wheel drive clutch pressure plate spring (15) for cracks.
18. Inspect the transfer case four wheel drive clutch pressure plate – friction (16) for worn, grooved, burnt, or flaking friction material, or warped friction plates.
19. Inspect transfer case four wheel drive clutch pressure plate – steel (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 driven sprocket engagement spline engagement teeth for excessive looseness on the front output shaft drive sprocket (21).
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) cam lobes for wear or roughness. Refer to: Transfer Case Range Actuator Learn if damage is found.
27. Inspect the transfer case two/four wheel drive actuator cam spacer for wear or roughness. Refer to: Transfer Case Range Actuator Learn if damage is found.