Inspection
INSPECTIONMAINSHAFT
Examine the mainshaft components carefully for evidence of wear or damage.
Replace the thrust washers if worn or damaged.
Replace the mainshaft and sprocket gears if the teeth or gear bores are worn or damaged.
Replace the mainshaft bearings if worn, flat spotted, brinelled, or damaged in any way.
Replace the mainshaft if it is bent, exhibits wear or damage to the bearing surfaces, splines or gear teeth.
INPUT GEAR
Check the input gear pilot bearing. Rotate the bearing and check for roughness or noise. Also check bearing position in the bore. The bearing should be installed such that the snap-ring on the outer diameter of the bearing is seated against the front case half. Replace the bearing if worn, or roughness is evident. Replace both the gear and bearing if the bearing is a loose fit in the bore.
During inspection, also make sure the seal surface of the input gear is in good condition. Minor nicks on this surface can be reduced with crocus cloth. However, replace the gear if the seal surface is severely scored or worn.
GEAR CASE AND RETAINERS
Examine both case halves and retainers carefully. Replace any retainer or case half if wear, cracks, or other damage is evident.
Check the bushing in the rear retainer. Replace the bushing if worn or scored.
Examine the sealing surfaces of both case halves and retainers. Small burrs, or scratches on these surfaces can be reduced with crocus cloth or a fine tooth file.
OIL PUMP AND PROGRESSIVE COUPLING
The oil pump and progressive coupling are not serviceable components. Replace the coupling as an assembly if it is damaged. Replace the oil pump as an assembly if the gear teeth are worn, or if the pump has become damaged.
BEARINGS AND SEALS
The transfer case seals should be replaced during overhaul. Use new seals in the input gear bearing retainer, front case and rear retainer. Also replace the yoke seal washer.
Check condition of each transfer case bearing. Replace any bearing exhibiting signs of roughness, wear, or damage.