Cleaning and Inspection

NV241LD - Transfer Case







CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts. INSPECTION MAINSHAFT/SPROCKET/HUB Inspect the splines on the hub and shaft and the teeth on the sprocket (Fig. 41). Minor nicks and scratches can be smoothed with an oilstone, however, replace any part that is damaged.

Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe. Inspect the spline teeth on the synchronizer hub. If evidence of chipping or excessive wear is apparent, replace the hub. The hooked end of each synchronizer 35 spring should be inserted in one of the struts. In addition, the springs should not interfere with the polished gear cone or inside diameters of the hub. Inspect the stop ring for cracks and wear. Replace the ring if necessary or if doubt exists over condition. Check a replacement synchronizer ring for proper fit on the cone with a minimum of wobble. Also check the synchronizer struts for wear or damage.



INSPECTION







INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 42). Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery cloth if necessary. Examine the carrier body and pinion gears for wear or damage. The carrier will have to be replaced, as an assembly if the body, pinion pins, or pinion gears are damaged. Check the lock ring and both thrust washers for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.






SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift rail (Fig. 43). Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.






Inspect the shift fork wear pads (Fig. 44). The mode fork pads are serviceable and can be replaced if necessary. The range fork pads are not serviceable. The fork must be replaced as an assembly if the pads are worn or damaged.

Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.


REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the bearing bore.

Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.

Inspect rear extension bushing. Replace if worn or scored.


DRIVE CHAIN
Examine the drive chain and shaft bearings, replace the chain if stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.







LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the gear (Fig. 45)


FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and damage. Replace the input retainer seal, do not reuse it.

Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/ drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary.

Or the threads can be repaired with Helicoil stainless steel inserts if required.

OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.