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• The retaining pins in the shift shaft are not 0.100" (2.54
mm) above the shaft diameter. Remove and set to the
correct position.
• Gouges on the inside of the shift cylinder.
• Torn or feathered areas on the o-ring.
• Deep gouges in the shifting bores of the case halves.
Oil and Lubrication System
The lubrication system is extremely important to the performance
of the transfer case. Inspect all parts closely for excessive wear or
damage. Perform the following checks:
1.
Inspect the oil for metal shavings, dirt, and consistency.
Perform an analysis if the oil appears contaminated.
2.
Check the magnets for metal shavings. A small amount
of metal shavings is normal. However, excessive build-up
indicates gear and bearing damage. Thoroughly remove all
metal shavings from the magnets. The magnets must be
firmly fastened to the case.
3.
Check the sump screen. Remove any material that may
restrict oil flow through the mesh.
4.
Check the oil line for damage. Replace if it is dented or
kinked.
Internal Oil Pump
1.
Inspect the seals closely. Look for nicks and tears on all
sealing lips. Any damage is likely to result in a seal leak.
2.
Check the pump for easy rotation. If the internal gear does not
spin easily or jams when rotating the crescent plate, replace
the pump. Also inspect for signs of heat/discoloration.
3.
Inspect the input shaft and oil pump splines for damage.
4.
Verify the relief valve spring and bushing are in good condition
and replace, if necessary.
External Rear-Mounted Oil Pump
1.
Verify the pump drive pins on the rear half of the input shaft
correctly engage the pump. If necessary, remove the pump
and reinstall it in the correct position.
2.
Inspect the pump gear for damage.
3.
Verify the transfer spring is in good condition.
4.
Once the transfer case has been installed on the vehicle,
verify the pump pressure is correct. Refer to the pump
pressure check instructions in the final assembly procedures
Printed in USA
6
Transfer Case Halves
Inspect the case halves for cracks and internal wear. If any of the
following conditions exist, replace the damaged parts.
• A crack in either case half.
• Deep gouges in the shifting bores.
• Signs of bearing cup rotation.
Preparing the Case and Cover for Seal
Replacement
1.
Pry out all oil seals using a suitable pry bar.
2.
As necessary, use a suitable puller to remove the bearing
cups pressed into the transfer case halves.
3.
Clean and inspect the transfer case and cover for cracks,
worn threaded holes or other wear or damage. Clean the
gasket surfaces of both transfer case halves using a suitable
gasket scraper or wire wheel.
4.
Press new bearing cups into the case halves as necessary.
Refer to "Assembly" for bearing settings and starting shim
pack procedures, if required.
5.
Inspect the bearing end play to ensure that it's within
specification. Adjust the end play, if required. Refer to
"Assembly".
6.
Install new oil seals into the case halves. Refer to Table H
on page 102 for correct seal part numbers and installation
tool kit numbers. Refer to the Service Notes page on the
front inside cover of this manual to obtain new seals and
installation tools. Refer to "Input Shaft Oil Seal and Yoke" on
page 72 for seal and sleeve installation instructions.
Copyright Meritor, Inc., 2022
Prepare Parts for Assembly
MM-0861 / Revised 06-22
Page 59
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