Transfer Case Front Half 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: Transfer Case Front Half Cleaning and Inspection

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
CAUTION: Refer to Machined Surface Damage Caution . 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 the front case half in cleaning solvent and air dry. Remove any sealant from the sealing surface.
1	Transfer Case Front Half Assembly Tip: Inspect for cracks, broken areas, or other damage. The component must be replaced if damage is found.
2	Transfer Case Front Output Shaft Front Bearing Bore Tip: Replace the front case half assembly if a bearing has spun or if cracks are detected.
3	Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Bore Tip: Replace the front case half assembly if a bearing has spun or if cracks are detected.
4	Transfer Case Studs (Qty: 6) Tip: Replace any damaged studs
5	Transfer Case Input Shaft Bearing Bore Tip: Replace the front case half assembly if a bearing has spun or if cracks are detected.
6	Case Sealing Surface Tip: Repair small scratches or nicks with a soft stone.
7	Transfer Case Thread Bolt Holes Tip: Repair any damaged threads.
8	Transfer Case Locating Pin Holes Tip: Replace the front case half assembly if the locating pin holes are out of round or damaged.
9	Transfer Case Locating pins (Qty: 2) Tip: Repair or replace loose, missing, or damaged locating pins.
10	Transfer Case High/Low Internal Gear Tip: Replace the front case half assembly if the gear is loose in the case, or if the gear teeth are chipped or embedded with debris.
11	Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Tip: Replace the bearing if roughness, brinelling, or pitting is detected. Refer to Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Replacement - Front .