Cleaning and Inspection

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
If any pump component is worn, or damaged, the pump must be replaced as an assembly.Inspect the spline teeth on the synchronizer hub (Fig. 38). If evidence of chipping or excessive wear is apparent, replace the hub. The hooked end of each synchronizer 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.

Inspect all gear teeth and splines for wear or damage. Also check splines for burrs, or nicks. Remove minor nicks and scratches with an oil stone. Replace any part with damaged splines.

It is recommended that all retaining rings be replaced during overhaul. Most of the retaining rings can be distorted during removal and should not be reused.

Inspect the two case halves, for cracks, porosity, damaged mating surfaces, stripped bolt threads, or distortion. Replace either case half if necessary. However, stripped threads can be repaired with Heli-Coil stainless steel thread inserts. The case vent tube can be re-secured with Loctite 680 if necessary.

Inspect the annulus gear. Be sure the gear teeth are in good condition. Replace the front case and annulus as an assembly if the gear is damaged.






Check condition of the shift fork pads (Fig. 39). The pads should be replaced if cracked, worn, or loose (won't stay on fork).






The shift forks, clutch and sleeve should all be checked for wear, cracks, or any type of damage (Fig. 40). The shift sector shaft and detents should be inspected for wear. The mode fork and shift rail are a one-piece unit. If either part is damaged, replace the fork and rail as an assembly. Replace the shift rail cup and spring if they exhibit wear.






Inspect the planetary thrust washers (Fig. 41) carefully for wear or damage. Replace both washers if necessary.

The planetary carrier cannot be disassembled. It must be serviced as an assembly if damaged. Check condition of the pinion teeth and PTO gear teeth. If pinion tooth wear is evident, it will also be necessary to check condition of the annulus gear teeth.