Contents: Crankcase and covers ↓ Seals ↓ Shafts ↓ Gears ↓ Rods, forks ↓ Hubs, couplings ↓ Differential ↓
Before inspection, thoroughly clean all parts of the transfer case with a brush and scraper, then wash. Blow off the parts with a jet of compressed air. Particularly thoroughly wash and blow off the bearings, not allowing them to rotate quickly from the jet of compressed air, so as not to damage them.
Crankcase and covers
There should be no cracks on the crankcase and covers, and no wear or damage is allowed on the surface of the bearing bores (dents, chips). Damage to the surfaces where the crankcase and covers meet may cause shaft misalignment and oil leakage. File off minor damage. Replace parts with new ones if damage or wear is significant.
Seals
Check their condition carefully. If even minor damage is detected, replace the seals with new ones. The wear width of the seal working edge should not exceed 1 mm.
Shafts
No damage is allowed on the working surfaces, threaded part and on the splines of the shafts. Check the runout of the drive shaft and the drive shafts of the front and rear axles by installing them on prisms and turning them manually. The runout of the end part of the thrust belts for bearings should be no more than 0.01 mm.
When checking the intermediate shaft, pay attention to the condition of the gear block and the speedometer drive pinion. No chipping or excessive wear of the teeth is allowed. Replace any defective parts.
Gears
When inspecting gears, check the condition of the teeth and mounting surfaces. Chipping of teeth and their excessive wear are not allowed. There should be no scoring or wear on the mounting surfaces of the gears that would cause a large gap.
Check the clearance in the gear engagement; the installation gap should be 0.10 mm, the maximum permissible is 0.20 mm.
The mounting clearance between the low gear pinion and the bushing, as well as between the drive shaft and the high gear pinion, should be 0.05-0.10 mm, the maximum permissible is 0.15 mm. If wear exceeds the permissible limits, replace the gears with new ones.
Bearings. Ball and roller bearings must not have damage on the raceways of the rings, on the separators, rollers or balls, as well as cracks and chips on the rings. The radial clearance of the bearings must not exceed 0.05 mm.
When turning, a clean, dry bearing should not knock. The movement should be smooth, without jamming. Replace damaged bearings.
Rods, forks
Deformation of the forks and sticking of the rods in the crankcase holes are not allowed. Replace the retainer parts with new ones if signs of sticking are detected. Also replace the retainer springs if they lose elasticity. Spring length under load 99.15-114.85 N (10.2-11.8 kgf) should be 19 mm, in a free state - 23.3 mm.
Hubs, couplings
Check for signs of seizing on the hub of the gear engagement clutch and especially on the sliding surfaces of the clutches, as well as on the splines of the differential housing. Clean up burrs and nicks with a file. Pay special attention to the condition of the ends of the clutch teeth; if they are damaged or crushed, preventing it from moving when shifting, replace the clutch.
Differential
Check the condition of the surface of the satellite shaft and the holes in the differential housing; in case of minor damage, sand the surfaces with fine-grained sandpaper, and in case of significant damage, replace the parts with new ones.
Check the condition of the surface of the axle drive gear necks and their mounting holes in the differential housings, as well as the condition of the bearing surfaces on the adjusting washers and the mating end surfaces on the axle drive housings and gears. Eliminate any damage found with fine-grained sandpaper or a velvet file; replace significantly damaged or worn parts.
With spring washer 15 removed (fig. 3-42) make sure that there is no radial movement of the retaining rings 8 in the grooves of the axle 14. If play is detected, replace the retaining rings.