2. Cleaning and Inspection

Cleaning and Inspection

Front Case Half





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

Notice: Refer to Machined Surface Damage Notice in Service Precautions.

2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Inspect the front output shaft front bearing bore (8) for:
^ Spun bearing
^ Cracks
5. Inspect the input shaft bearing bore (5) for:
^ Spun bearing
^ Cracks
6. Replace the front case half if any of the above is found.
7. Inspect the sealing surfaces 0 11 for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the front case to transmission case mounting surface for damage.
10. Inspect the case threaded bolt holes (2) for damage.
11. Repair any damaged threads
12. Inspect the transmission to transfer case studs (4) for damage.
13. Replace any damaged studs
14. Inspect the retaining ring (3) of the annulus gear to ensure it is properly seated.
15. Inspect the annulus gear (6) for the following:
^ Damage or wear
^ Chipped gear teeth
^ Debris embedded in the tool of the teeth
16. Replace the front case half it the annulus gear is damaged.
17. Inspect the control actuator lever shaft bearing and seal (7) for the following:
^ Roughness
^ Pitted rollers
^ Seal torn or damaged
18. Replace the control actuator lever shaft bearing if it is faulty.
19. inspect the location pit-is for being loose or missing.
20. Repair or replace any damaged location pins.
21. Inspect the front output shaft front bearing and the input shaft bearing for the following:
^ Roughness
^ Brinneling
^ Pitting
22. Replace the bearings if any of the above conditions are found.

Rear Case Half





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

Notice: Refer to Machined Surface Damage Notice in Service Precautions.

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 for damage.
8. Repair any damaged threads.
9. Inspect the oil pump retainer (5) for wear or damage.
10. Replace the oil pump retainer if faulty.
11. Inspect the front output shaft rear bearing (4) for the following:
^ Roughness
^ Brinneling
^ Pitting
12. Replace the front output shaft rear bearing if any of the above conditions are found.
13. Inspect the rear output shaft bearing for the following:
^ Roughness
^ Brinneling
^ Pitting
14. Inspect for a spun bearing bore for the rear output shaft rear bearing.
15. Replace the case if a bearing has spun.
16. Inspect the retaining ring (2) for the rear output shaft rear bearing for being bent or twisted.
17. Replace a faulty retaining ring.
18. Inspect the rear output shaft bushing (3) for scoring or wear.
19. Replace a faulty rear output shaft bushing.





20. Remove the oil pump suction pipe and the oil pump suction hose from the oil pump screen.
21. Clean the pipe, hose, and screen in cleaning solvent and air dry.
22. If the screen is embedded with debris, replace the screen.
23. Inspect the hose for cracking or tears.
24. Replace the hose if it is faulty.

Rear Output Shaft





1. Clean the rear output shaft in cleaning solvent.
2. Clean the rear output shaft oil galleries (2), and air dry.

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

3. Inspect the input gear pilot bearing surface (1) and the drive gear sleeve journal surface (4) for the following:
^ Scoring
^ Pitting
^ Brinneling
^ Excessive wear
4. Inspect the rear output shaft splines (3) for damage or excessive wear. Witness marks at the location of the gears is normal.
5. Replace the rear output shaft it any of the above conditions are found.

High/Low Planetary Carrier





1. Clean the high/low planetary carrier in cleaning solvent. Do not disassemble the planetary carrier.
2. Air dry, and ensure all cleaning solvent is removed from the bearings in the planetary gears (3). Do riot spin the planetary gears with compressed air.
3. Inspect the planetary gears for chipped teeth.
4. Inspect the planetary gears for debris embedded in the root of the teeth.
5. Inspect for a washer (4) being on each side of the planetary gears.
6. Inspect the low range teeth (1) for damage or excessive wear.
7. Inspect the thrust washer surface (2) for scoring or excessive wear.
8. Replace the high/low planetary carrier if any of the above conditions are found.
9. Inspect the high/low planetary thrust washers for excessive wear or scoring.
10. Replace the thrust washers if they are faulty.

Drive Chain and Sprockets





1. Clean the drive chain (1), drive sprocket (3), and driven sprocket (2) in cleaning solvent and air dry.
2. Inspect the drive chain (1) for the following:
^ Loose link pins
^ Binding or stiff links
^ Debris embedded in the links
^ Worn teeth surfaces
3. Replace the chain if any of the above conditions are found.
4. Inspect the driven sprocket (2) and the drive sprocket (3) for the following:
^ Chipped teeth
^ Excessive worn gear surfaces, slight wear marks are normal
^ Debris embedded in the root of the teeth
5. Replace the sprocket if any of the above conditions are found. The chain and sprockets may be replaced separately.





6. Inspect the drive sprocket sleeve journal surface for the following conditions:
^ Gouging
^ Roughness
^ Excessive wear
7. Replace the sprocket sleeve if faulty.

Front Output Shaft





1. Clean the front output shaft in cleaning solvent and air dry.
2. Inspect the front output shaft rear bearing race (1) for the following:
^ Scoring
^ Pitting
^ Brinneling
^ Excessive wear
3. Replace the faulty front output shaft rear bearing race.
4. Inspect the front output shaft splines (2) for damage.
5. Replace the front output shaft if it is damaged.

Input Gear





1. Clean the input gear, with pilot bearing, in cleaning solvent.
2. Air dry, and ensure all solvent is removed from the pilot bearing.
3. Inspect the pilot bearing (1) for the following:
^ Pitted
^ Wear
^ Corrosion
4. Replace the input gear pilot bearing (1) and the cup plug (2) if any of the above conditions are found.
5. Inspect the input gear engagement teeth (3) for chips.
6. Inspect the input gear for broken or damaged planetary teeth (4).
7. Inspect the input gear for debris embedded in the mot of the teeth.
8. Inspect the input gear seal surface (5) for pitting or excessive wear.
9. Replace the input gear if any of the above conditions are found.

Shift System Components





1. Clean the following shift system components in cleaning solvent and air dry:
^ The high/low shift fork (1)
^ The range sleeve (2)
^ The two/four wheel drive mode shift fork (3)
^ The shift fork shaft (4)
^ The control actuator lever shaft (5)
^ The synchronizer gear clutch (6)
^ The synchronizer assembly (7)
2. Inspect the shift fork shaft for straightness (4).
3. Replace the shift fork shaft if it is not straight.
4. Inspect the synchronizer gear clutch (6) for chipped or worn engagement teeth.
5. Replace the gear clutch if faulty.





6. Inspect the pads (1) on the shift fork for wear.
7. Inspect the roller (2) on the shift fork for wear.
8. Replace the shift fork if the roller is worn or the pads are worn.





Important: Only disassemble the shift fork assembly if replacing a faulty component.

9. Inspect the following components of the shift fork assembly for wear or damage:
^ The spring (2)
^ The washers (3)
^ The bracket (4)
^ The shift fork (1)





10. Inspect the two/four wheel drive mode shift fork roller (1) for the following:
^ Wear
^ Rotates easily
11. Inspect the shift fork for worn wear pads (3).
12. Inspect the shift fork bearing (2) for being faulty.
13. Replace the shift fork if the above conditions are found.





14. Inspect the range sleeve for chipped or excessive worn teeth (1).
15. Inspect the shift fork collar (2) on the range sleeve for wear.
16. Inspect the inner splines (3) of the range sleeve for excessive looseness on the input shaft.
17. Replace the range sleeve if the above conditions are found.





18. Inspect the high/low shift fork roller slot (2) on the control actuator lever shaft for wear or roughness.
19. Inspect the bearing (1) and the seal surface on the control actuator lever shaft for the following:
^ Pitted
^ Wear
^ Corrosion
20. Inspect the two/four wheel drive mode shift fork cam lobes (3) on the control actuator lever shaft for wear or roughness.
21. Inspect the detent plunger cam lobes (4) for wear or roughness.
22. Replace the control actuator lever shaft if any of the above conditions are found.





23. Inspect the inner synchronizer ring (1) for wear and roughness.
24. Inspect the middle synchronizer ring (2) friction material for wear or damage.
25. Inspect the outer synchronizer ring (3) for wear.
26. Inspect the synchronizer sleeve (4) for the following conditions:
^ Wear on the engagement teeth
^ Wear in the insert notches
27. Inspect the synchronizer hub (6) for the following conditions:
^ Loose fit on the mainshaft
^ Broken or damaged insert springs (5 and 8)
^ Worn inserts (7)
28. Replace the synchronizer assembly if any of the above parts are faulty.