Gears
Check for wear, cracks, damage and scoring on the end surfaces of the gears and on the shaft.
Attention: In case of abnormalities in the drive gear or drive gear, replace both gears as a set.
Transfer case housing
1. Remove the pinion clutch assembly.
2. Remove the adapter body.
3. Remove the drive gear assembly from the transfer case housing.
4. Using a screwdriver or similar tool, remove the oil seal.
Caution: Do not damage the transfer case housing.
5. Remove the oil deflector.
Bearings
Check for scoring, flaking, wear, corrosion, sticking/abnormal knocking/sticking when turning by hand, and other damage.
In case of deviations from the norm, change the inner and outer races of the bearing as a set.
6. Remove the magnet.
7. Using a brass pin or similar tool, lightly tap the shim and ring gear bearing outer race through the two slots in the transfer case housing.
8. Unscrew the filler plug, remove the breather hose.