Transfer Case Cleaning and Inspection

Transfer Case Cleaning and Inspection

Transfer Case Housing




1. Clean the front case half in cleaning solvent and air dry.
2. Remove the metal shavings from the case half bolt holes.

Caution: Refer to Machined Surface Damage Caution (Machined Surface Damage Caution).

3. Remove the sealer from the case sealing surfaces.
4. Inspect the case for being broken or cracked.
5. Inspect the input shaft front bearing bore (4) for the following conditions:

* Scoring
* Cracks

6. Inspect the idler shaft front bearing bore (5) for the following conditions:

* Scoring
* Cracks

7. Replace the front case half if any of the above conditions are found.
8. Inspect the sealing surfaces (3) for damage.
9. Repair small scratches or nicks with a soft stone.
10. Inspect the transfer case housing to transmission case mounting surface for damage.
11. Inspect the case threaded bolt holes (2) for damage.
12. Repair any damaged threads.
13. Inspect the location pins (1) for being loose or missing.
14. Repair or replace any damaged location pins.
15. Inspect the idler shaft bearing and the input shaft bearing for the following conditions:

* Roughness
* Brinelling
* Pitting

16. Replace the bearings if any of the above conditions are found. Refer to Transfer Case Disassemble (Transfer Case Disassemble) and Transfer Case Assemble (Transfer Case Assemble).

Rear Extension Housing




1. Clean the rear case half in cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution (Machined Surface Damage Caution).

2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Replace the case if it is broken or cracked.
5. Inspect the sealing surfaces (1) for damage.
6. Repair small scratches or nicks with a soft stone.
7. Inspect the case threaded bolt holes (2) for damage.
8. Repair any damaged threads.
9. Inspect the input shaft rear bearing bore (4) for the following conditions:

* Scoring
* Cracks

10. Inspect the idler shaft rear bearing bore (3) for the following conditions:

* Scoring
* Cracks

11. Replace the case if any of the above conditions are found.

Input Shaft




1. Clean the input shaft in cleaning solvent.
2. Inspect the input shaft splines (1) for excessive wear or damage.
3. Inspect the input seal surface (2) for excessive grooves or damage.

Note: Do not attempt to smooth any roughness in the bearing journals.

4. Inspect the bearing journals (3 and 6) on the input shaft for the following conditions:

* Scoring
* Pitting
* Brinelling
* Excessive wear

5. Inspect the input shaft gear teeth (4) for excessive wear or damage.
6. Inspect the input shaft bearing retainer rear seal surface (5) for excessive grooves or damage.
7. Replace the input shaft if any of the above conditions are found.

Idler Shaft




1. Inspect the bearing journals (1 and 3) on the idler shaft for the following conditions:

* Scoring
* Pitting
* Brinelling
* Excessive wear

2. Inspect the idler shaft gear teeth (2) for excessive wear or damage.
3. Replace the idler shaft if any of the above conditions are found.

Rear Output Shaft




1. Clean the rear output shaft with rear output shaft bearing in cleaning solvent.
2. Air dry and ensure all solvent is removed from the bearing.
3. Inspect the rear output shaft bearing journals (2) for the following conditions:

* Scoring
* Pitting
* Brinelling
* Excessive wear

4. Inspect the rear output shaft seal surface (1) for excessive grooves or damage.
5. Inspect the rear output shaft gear teeth (3) for excessive wear or damage.
6. Replace the rear output shaft if any of the above conditions are found.