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 (8) for the following conditions:
- Inspect the input shaft bearing bore (5) 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 (4) for damage.
- Replace any damaged studs. Refer to
Transfer Case Assemble .
- Inspect the retaining ring (3) of the annulus gear to ensure it is properly seated.
- Inspect the annulus gear (6) for the following conditions:
| • | Debris embedded in the root of the teeth |
- Replace the front case half if the annulus gear is damaged. The annulus gear is serviced only with the front case half.
- Inspect the control actuator lever shaft bearing and seal (7) for the following conditions:
- Replace the control actuator lever shaft bearing if it is 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 it is 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 the rear output shaft rear bearing for a spun bearing bore.
- 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 output shaft bushing (3) for scoring or wear.
- Replace a faulty rear output shaft 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 in the bearing journals.
- Inspect the input gear pilot bearing surface (2) and the clutch housing bearing surface (3) for the following conditions:
- Inspect the splines on the rear output shaft 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 worn or warped. If the discs show wavey wear marks, the discs are faulty.
- 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 pressure plate hub (1) in cleaning solvent and air dry.
- Inspect the pressure plate bearing (2) for the following conditions:
- Replace the pressure plate bearing if it is 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 return 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 burrs or excessive wear. Excessive wear is identified by the steps in the teeth, which prevents the clutch disc from moving freely.
- Remove any burrs from the clutch housing disc teeth.
- 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.
High/Low Planetary Carrier
Important: Depending on the version of the transfer case, it may have either a 3 pinion gear or 6 pinion gear planetary carrier assembly. The 3 pinion gear planetary carrier is used with transmission RPO M30
and the input gear splines are 27 teeth. The 6 pinion gear planetary carrier is used with transmission RPO MT1 and MN8 and the input gear splines are 32 teeth. The repair procedures are the same for both planetary carriers.
- Clean the high/low planetary carrier in cleaning solvent. Do not disassemble the planetary carrier.
- Air dry and ensure all cleaning solvent is removed from the bearings in the planetary gears (3). Do not spin the planetary gears with compressed air.
- Inspect the planetary gears for chipped teeth.
- Inspect the planetary gears for debris embedded in the root of the teeth.
- Inspect for a washer (4) being on each side of the planetary gears.
- Inspect the low range teeth (1) for damage or excessive wear.
- Inspect the thrust washer surface (2) for scoring or excessive wear.
- Replace the high/low planetary carrier if any of 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 (3) for damage.
- Replace the speed sensor reluctor wheel if it is 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 (2) for damage.
- Replace the front output shaft if any of the above conditions are found.
Input Gear
- Clean the input gear, with pilot bearing, in cleaning solvent.
- Air dry and ensure all solvent is removed from the pilot bearing.
- Inspect the pilot bearing (1) 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 engagement teeth (2) for chips.
- Inspect the input gear for broken or damaged planetary teeth (3).
- Inspect the input gear for debris embedded in the root of the teeth.
- Inspect the input gear seal surface (4) for pitting or excessive wear.
- Replace the input gear if any of the above conditions are found.
- Inspect the input gear thrust washers for excessive wear or scoring.
- Replace the thrust washers if they are faulty.
Shift System Components
- Clean the following shift system components in cleaning solvent and air dry:
| • | The high/low shift fork (1) |
| • | The shift fork shaft (4) |
| • | The control actuator lever shaft (5) |
- Inspect the shift fork shaft for straightness (4).
- Replace the shift fork shaft if it is not straight.
- Inspect the pads (2) on the shift fork for wear or breakage.
- Replace the pads if worn or broken.
- Inspect the roller (1) on the shift fork for wear or damage.
- Replace the shift fork if the roller is faulty.
Important: Do not disassemble the shift fork. Replace as an assembly only.
- Inspect the following components of the shift fork assembly for wear or damage:
- Replace the shift fork assembly if any of the above components are faulty.
- 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 if the above conditions are found.
- Inspect the range sleeve for chipped or excessively worn teeth (1).
- Inspect the shift fork collar (2) on the range sleeve for wear.
- Inspect the inner splines (3) of the range sleeve for excessive looseness on the rear output shaft.
- Replace the range sleeve if the above conditions are found.
- Inspect the shift fork roller slot (1) on the control actuator lever shaft for excessive wear or roughness.
- Inspect the bearing (2) and the seal surface on the control actuator lever shaft for the following conditions:
- Inspect the clutch lever cam lobes (3) on the control actuator lever shaft for excessive wear or roughness.
- Replace the control actuator lever shaft if any of the above conditions are found.
