Transfer Case: Service Precautions

PRECAUTION
^ Before disassembly, clean the transfer assy and remove any deposited sand or mud to prevent it from entering the inside of the transfer during disassembly and assembly.
^ When removing any light alloy part such as a transfer cover, do not pry it off with a tool like a screwdriver but tap it out with a plastic hammer.
^ Always organize the removed parts properly and protect them away from dust.
^ After cleaning and drying completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts and ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean the rubber parts such as O-rings and oil seals.
^ Sufficiently apply hypoid gear oil to any sliding surface or rotating part.
^ Do not directly hold a part by vise. Make sure to put an aluminum sheet between them.
^ Replace any damaged or deformed snap ring with new one.
^ If mating surface of the case is scratched, it may cause oil leakage. Therefore, carefully avoid such damage when handling.
^ Before applying a sealant, completely remove old sealant stuck on the sealed parts and clean them with white gasoline.
^ Do not supply oil immediately after installing sealed parts. Allow 1 hour or more.
^ Scratches on a contact surface with an oil seal, O-ring or gasket may result in oil leakage. Carefully avoid such damage when handling.
^ When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged.
^ When replacing a bearing, replace both outer and inner races as one set.