Caution: Refer to Machined Surface Damage Caution in the Preface section.

Preliminary Procedures

1. 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.
2. Clean the left and right transfer case in cleaning solvent and air dry.

1

Transfer Case - Left and Right

Tip
Inspect for cracks, broken areas, or other damage. The transfer case assembly must be replaced if damage is found.

2

Transfer Case Rear Output Drive Housing Bore

Tip
Repair small scratches or nicks with light sanding.

3

Case Sealing Surface

Tip
Repair small scratches or nicks with a soft stone.

4

Transfer Case Bearing Races

Tip
Replace the transfer case assembly if a bearing has spun or if cracks are detected.

5

Transfer Case Thread Bolt Holes

Tip
Repair any damaged threads.

6

Transfer Case Half Locating Pin Holes