Front Output Shaft and Input Shaft Cleaning and Inspection

WARNING: This page is about a different car, the 2009 GMC Yukon, 2009 Chevrolet Tahoe, 2009 Chevrolet Suburban, and 2009 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Front Output Shaft and Input Shaft Cleaning and Inspection

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
Preliminary Procedure Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry.
1	Transfer Case Input Shaft Seal Surface Tip: Inspect for pitting, excessive wear, or damage.
2	Transfer Case Input Shaft Bearing Surface Tip: Inspect for excessive wear, damage, or if the bearing has spun on the shaft.
3	Transfer Case Input Shaft Planetary Teeth Tip: Inspect for broken, damaged, or debris embedded in the root of the teeth.
4	Transfer Case Input Shaft Pilot Bearing Surface Tip: If the bearing is removed, inspect for excessive wear, damage, or if the bearing has spun in the bore.
5	Transfer Case High/Low Clutch Engagement Teeth Tip: Inspect the engagement teeth for chips or excessive wear.
6	Transfer Case Input Shaft Pilot Bearing Assembly Tip: Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Input Shaft Pilot Bearing Replacement (Light Duty) or Input Shaft Pilot Bearing Replacement (Heavy Duty and Super Heavy Duty) .
7	Transfer Case Input Shaft Pilot Bearing Assembly Retaining Ring (HD only)
8	Transfer Case Front Output Shaft Front Bearing Assembly Tip: Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Front Output Shaft Front and Rear Bearing Replacement .
9	Transfer Case Front Output Shaft Seal Surface Tip: Inspect for pitting, excessive wear, or damage.
10	Transfer Case Front Output Shaft Front Bearing Surface Tip: If the bearing is removed, inspect for excessive wear, damage, or if the bearing has spun on the shaft.
11	Transfer Case Front Output Shaft Driven Sprocket Engagement Splines Tip: Witness marks at the location of the sprocket is normal.
12	Transfer Case Front Output Shaft Rear Bearing Surface Tip: If the bearing is removed, inspect for excessive wear, damage, or if the bearing has spun on the shaft.
13	Transfer Case Front Output Shaft Hole Plug Tip: Replace the plug if removed. Refer to Front Output Shaft Front and Rear Bearing Replacement .
14	Transfer Case Front Output Shaft Rear Bearing Assembly Tip: Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Front Output Shaft Front and Rear Bearing Replacement .