Skip to content
Tahoe / Yukon Service Manual

Transfer Case Front Half Cleaning and Inspection

Transfer Case Front Half Cleaning and Inspection — figure 1
Transfer Case Front Half Cleaning and Inspection — figure 1
  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 front case half in cleaning solvent and air dry.
  3. Remove any sealant from the sealing surface.
  4. Inspect transfer case front half (1) for excessive wear, cracks, or damage. The component must be replaced if damage is found.
  5. Transfer Case Front Output Shaft Front Bearing Bore (2) » Replace the front case half assembly if a bearing has spun or if cracks are detected.
  6. Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Bore (3) » Replace the front case half assembly if a bearing has spun or if cracks are detected.
  7. Transfer Case Stud  [6x] (4) » Replace any damaged studs.
  8. Transfer Case Input Shaft Bearing Bore (5) » Replace the front case half assembly if a bearing has spun or if cracks are detected.
  9. Inspect the case sealing surface (6). Repair small scratches or nicks with a soft stone.
  10. Inspect the transfer case thread bolt hole (7). Repair any damaged threads.
  11. Inspect the transfer case locating pin holes (8). Replace the front case half assembly if the locating pin holes are out of round or damaged.
  12. Inspect the 2 transfer case pins (9). Repair or replace loose, missing, or damaged locating pins. h f h h/l l ( )
  13. Inspect the transfer case high/low internal gear (10). Replace the front case half assembly if the gear is loose in the case, or if the gear teeth are chipped or embedded with debris.
  14. Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing (11) » Replace the bearing if roughness, brinelling, or pitting is detected. Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Replacement - Front