Cleaning And Inspection

CLEANING: 

• Clean the transfer case parts with a standard parts cleaning solvent.
• Clean the Loctite™ from the threads with a thread chaser before installing new motor bolts. Installing new bolts with Loctite™ can cause the case to crack and damage the case half if the old Loctite™ sealer is not removed.
• Remove all traces of sealer from the cases and retainers with a scraper and 3M™ all purpose cleaner.
• Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.

INSPECTION: 

FRONT AND REAR CASES 

• Inspect the case halves for wear and damage.
• Check case for gouges and severe scoring of case half sealing surfaces.
• Check the threads in the case half bolt holes. The threads can be cleaned up with a thread chaser if necessary.
• Inspect the worm shaft for damage. If the worm shaft is damaged, the rear case half must be replaced.
• Check all bearings in the case halves for fatigue or pitting. Replace the bearings if rough, noisy or any damage is found.
• Examine the chain guides for signs of wear.
• Inspect the splines on the output shafts.
• Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in the rear case.

INTERNAL COMPONENTS 

• Inspect the worm gear teeth on the shift shaft for damage or wear.
• Check the bearings on the main shaft and clutch for fatigue or pitting. Replace the bearings if rough, noisy or any damage is found.
• Examine the drive chain and front output sprocket. Replace the chain if stretched, distorted, or if any of the links bind. Replace the sprocket if the teeth are damaged.
• Check the planetary gears for any damage.
• Check the teeth on the annulus gear for damage.
• Check all snap rings and thrust washers for excessive wear or damage.