Front Case Half
- Clean the front case half in cleaning solvent and air
dry.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Remove the sealer from the case sealing surfaces.
- Inspect the case for being broken or cracked.
- Inspect the front output shaft front bearing bore (6) for the
following conditions:
- Inspect the input shaft bearing bore (4) for the following conditions:
- Replace the front case half if any of the above conditions are found.
- Inspect the sealing surfaces (1) for damage.
- Repair small scratches or nicks with a soft stone.
- Inspect the front case to transmission case mounting surface for damage.
- Inspect the case threaded bolt holes (2) for damage.
- Repair any damaged threads.
- Inspect the transmission to transfer case studs (3) for damage.
- Replace any damaged studs. Refer to
Transfer Case Assemble
.
- Inspect the control actuator lever shaft bearing and seal (5)
for the following conditions :
- Replace the control actuator lever shaft bearing if faulty. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the location pins for being loose or missing.
- Repair or replace any damaged location pins.
- Inspect the front output shaft front bearing and the input shaft bearing
for the following conditions:
- Replace the bearings if any of the above conditions are found. Refer
to
Transfer Case Disassemble
and
Transfer Case Assemble
.
Rear Case Half
- Clean the rear case half in cleaning solvent and air
dry.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Remove the sealer from the case sealing surfaces.
- Inspect the case for being broken or cracked.
- Replace the case if broken or cracked.
- Inspect the sealing surfaces (1) for damage.
- Repair small scratches or nicks with a soft stone.
- Inspect the case threaded bolt holes for damage.
- Repair any damaged threads.
- Inspect the oil pump wear sleeve (5) for wear or damage.
- Replace the oil pump wear sleeve if faulty.
- Inspect the front output shaft rear bearing (4) for the following
conditions:
- Replace the front output shaft rear bearing if any of the above conditions
are found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the rear output shaft bearing for the following conditions:
- Inspect for a spun bearing bore for the rear output shaft rear bearing.
- Replace the case if a bearing has spun.
- Inspect the rear output shaft rear bearing retaining ring (2)
for being bent or twisted.
- Replace a faulty retaining ring.
- Inspect the rear case bushing (3) for scoring or wear.
- Replace a faulty rear case bushing. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
Oil Pump
- Clean the oil pump suction pipe, with the screen,
in cleaning solvent and air dry. Do not remove the screen from the pipe.
- If the screen is embedded with debris, replace the suction pipe assembly.
- Inspect the oil pump for free movement.
- Replace the oil pump if there is any binding. Do not disassemble the
oil pump. The oil pump is serviced as a unit.
Rear Output Shaft
- Clean the rear output shaft in cleaning solvent.
- Clean the rear output shaft oil galleries (1) and air dry.
Important: Do not attempt to smooth any roughness on
the bearing journals.
- Inspect the input gear pilot bearing surface (2) and the clutch housing
bearing surface (3) for the following conditions:
- Inspect the rear output shaft splines (4) for damage or excessive
wear. Witness marks at the location of the gears are normal.
- Replace the rear output shaft if any of the above conditions are found.
Clutch Components
- Do not clean the inner clutch discs (1) in
cleaning solvent.
- Inspect the inner clutch discs (1), with the friction material,
for the following conditions:
| • | Grooved or scored friction material |
- Inspect the outer clutch discs (2) steel plates for being grooved.
- Inspect the outer clutch discs (2) for a wavey wear pattern.
- Replace the clutch discs if any of the above conditions are found.
- Clean the clutch pressure plate (3), the clutch
pressure plate bearing (2) and the clutch bearing inner support (1)
in cleaning solvent and air dry.
- Inspect the pressure plate bearing (2) for the following conditions:
- Replace the pressure plate bearing if damaged or worn.
- Inspect the clutch pressure plate (3) for wear or damage.
- Replace a faulty clutch pressure plate.
- Inspect the clutch pressure plate bearing hub (1) for wear or
damage.
- Replace a faulty clutch pressure plate bearing hub.
- Inspect for a damaged clutch spring (4).
- Replace a faulty clutch spring.
- Clean the clutch housing, with the bearing, in cleaning
solvent.
- Air dry and ensure all solvent is removed from the bearing.
- Inspect the bearing for wear or damage.
- Replace the clutch housing bearing if faulty. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the clutch housing disc teeth for excessive wear. Excessive wear
can be identified by the steps in the teeth, which prevents the clutch disc from moving
freely.
- Replace the clutch housing if the clutch disc teeth cannot be deburred.
- Clean the clutch hub in cleaning solvent and air dry.
- Inspect the clutch disc surface (3) for excessive wear, warpage,
or grooves.
- Inspect the rear output shaft to the clutch inner hub splines (1)
for excessive looseness.
- Inspect the clutch hub teeth (4) for excessive wear. Steps in the
teeth can identify excessive wear, which prevents the clutch disc from moving freely.
- Inspect the clutch pressure plate tab slots (2) for excessive wear.
- Replace the clutch hub if any of the above conditions are found.
- Clean the clutch lever assembly in cleaning solvent
and air dry.
- Inspect the clutch lever roller (2) for the following conditions:
- Inspect the clutch lever for worn wear pads (1).
- Inspect the clutch lever for wear at the pivot pin holes (3).
- Replace the clutch lever assembly if the above conditions are found.
Drive Chain and Sprockets
- Clean the drive chain (1), drive sprocket (3),
and driven sprocket (2) in cleaning solvent and air dry.
- Inspect the drive chain (1) for the following conditions:
| • | Debris embedded in the links |
- Replace the chain if any of the above conditions are found.
- Inspect the driven sprocket (2) and the drive sprocket (3)
for the following conditions:
| • | Excessively worn gear surfaces |
| • | Slight wear marks are normal. |
| • | Debris embedded in the root of the teeth |
- Replace the sprocket if any of the above conditions are found. The chain
and sprockets may be replaced separately.
Front Output Shaft
- Clean the front output shaft in cleaning solvent and
air dry.
- Inspect the teeth on the speed sensor reluctor wheel (2) for damage.
- Replace the speed sensor reluctor wheel if damaged. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the front output shaft rear bearing race (1) for the following
conditions:
- Inspect the front output shaft splines (3) for damage.
- Inspect the front output shaft seal surface (4) for wear or roughness.
- Replace the front output shaft if any of the above conditions are found.
Input Gear
- Clean the input gear, with bearings, in cleaning solvent.
- Air dry and ensure all solvent is removed from the bearings.
- Inspect the input gear bearing for the following conditions:
- Replace the input gear bearing if any of the above conditions are found.
Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the input gear pilot bearing for the following
conditions:
- Replace the input gear pilot bearing if any of the above conditions are
found. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
.
- Inspect the input gear seal surface for pitting or excessive wear.
- Inspect the input gear internal splines for excessive wear.
- Replace the input gear if any of the above conditions are found.
