Transfer Case Rear 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 Rear 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 rear case half in cleaning solvent and air dry. Remove any sealant from the sealing surface.
1	Transfer Case Rear Case Half Assembly Tip: Inspect for cracks, broken areas, or other damage. The component must be replaced if damage is found.
2	Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring Groove Tip: Replace the rear case half assembly if the groove is worn.
3	Vehicle Speed Sensor Threads Tip: Replace the rear case half assembly if the speed sensor threads are damaged.
4	Transfer Case Rear Output Shaft Rear Bearing Bore Tip: Replace the rear case half assembly if a bearing has spun or if cracks are detected.
5	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.
6	Case Sealing Surface Tip: Repair small scratches or nicks with a soft stone.
7	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 - Rear .
8	Transfer Case Front Output Shaft Rear Bearing Bore Tip: Replace the rear case half assembly if a bearing has spun or if cracks are detected.
9	Transfer Case Locating Pin Holes Tip: Replace the rear case half assembly if the locating pin holes are out of round or damaged.
10	Transfer Case Rear Output Shaft Bushing Tip: Replace the bushing if it is damaged or worn. Refer to Transfer Case Disassemble and Transfer Case Assemble . If the bushing is removed, inspect the bushing bore for signs of spinning. Replace the rear case half assembly if the bushing has spun.