Transfer Case Cleaning and Inspection
- CAUTION:
Refer to Machined Surface Damage Caution .
NOTE:The case halves, idler gear, and idler gear bearings and races are not available as separate service parts. If component replacement is required, the transfer case is to be replaced as an assembly.
Inspect all components or sub-components and perform any repair procedure necessary to fix the damage.
- Inspect and remove any sealer from the case sealing surfaces (5).
- Clean the front case (4) and rear case (2) in cleaning solvent and air dry.
- Inspect for cracks, broken areas, or other damage. Repair small scratches on the sealing surfaces with light sanding.
- Inspect rear case bearing race bores (1)
- Inspect plug holes (3)
- Inspect front case bearing race bores (6)
Clean the shafts in solvent and air dry, including the input shaft oil galleries.
- Inspect all components or sub-components and perform any repair procedure necessary to fix the damage.
- Inspect the splines (1) for damage or excessive wear. Witness marks are normal.
- Inspect the plug area (2) for scoring, rust or other damage.
- Inspect the bearing journals (3) for scoring, pitting, or excessive wear.
- Inspect the splines (4) for damage or excessive wear. Witness marks are normal.
- Inspect the front output shaft snap ring groove (5) for damage.
- Inspect the front output shaft sealing surface (6) for scoring, rust or other damage.
Clean all components in solvent and air dry.
- Inspect all components or sub-components and perform any repair procedure necessary to fix the damage.
- Inspect the stud threads (1) and coil O-rings for damage.
- Inspect the wires and terminals (2) for damage. Repair, as required.
- Check the clutch coil resistance, should not exceed 2.5-3.5 ohms at 20°C (68°F).
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Courtesy of GENERAL MOTORS COMPANY
Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. The clutch pack is only available for service as an assembly. If the clutch pack assembly is replaced, reprogramming of the transfer case module is required. Refer to K69 Transfer Case Control Module: Programming and Setup , and Transfer Case Information Label .
- Do not clean the clutch friction plates in solvent.
- Other components may be cleaned in solvent.
- Small scratches or wear are allowed. Deep gouges or raised metal on the armature (1) require transfer case replacement and transfer case module reprogramming.
- Inspect the pressure plate (2) for flatness, warping, or scoring to the friction plate contact surface.
- The clutch friction plates (3) are assembled with the lube holes aligned as indicated in order to provide an unrestricted oil path when assembled.
- The clutch plates (4) are assembled with the lube holes aligned as indicated in order to provide an unrestricted oil path when assembled.
- Inspect the clutch hub (5) for worn, scored, or burnt friction material.
- Transfer case thrust washer (6) for excessive wear or damage.
- Inspect the clutch drum (7) for excessive wear or damage. Excessive wear can be identified by steps in the teeth, which prevent the plates from moving freely.
- If the clutch pack assembly (8) is replaced, reprogramming of the transfer case module is required. K69 Transfer Case Control Module: Programming and Setup
Do not attempt to smooth roughness in the bearing journals.
The clutch coil wire and stud O-ring seals are not serviceable separately. If O-ring seal damage is present, replace the clutch coil and seals as an assembly.