GMC 1989 Light Duty Truck, Repair Manual, Page: 959 / 998

NEW PROCESS 241 TRANSFER CASE 7D2-7
21.
22
.
23.
@3
Front output rear bearing (24) from the rear case
half (17).
• Insert J 29369-2 behind the needle bearings.
• Using J 2619-5, hammer the bearing from the
case (figure 9).
M ainshaft bearing (6) from the oil pump retainer (8).
Magnet (25) from the front case half (45).
D isassem ble
Scribe location of synchronizer hub and sleeve to
aid in assembly.
1. Main drive synchronizer stop ring (28) from the
synchronizer sleeve (29).
2. Spring retainer (32) from the synchronizer sleeve
(29).
3. Synchronizer hub (31) from the synchronizer (29).
4. Oil pump screws (79) from the oil pump (12).
5. Inner gears.
CLEANING AND INSPECTION
Clean
Bearings.
• Remove all old lubricant and dirt.
Shafts.
Sprockets.
Chain.
Oil feed ports and channels in each case half. Apply
compressed air to each oil feed port and channel in
order to remove any obstructions or cleaning solvent
residue.
All mating and sealing surfaces.
Inspect
1. Bearings and thrust washers for wear, spalling, brin-
neling, or corrosion.
2. Gear teeth for excessive wear or damage, spalling,
cracks, or corrosion.
3. Gear splines for excessive wear, spalling, cracks,
twist or corrosion.
6
.
L®
4. Shaft splines for excessive wear, spalling, cracks,
distortion or corrosion.
5. Retainer rings for excessive wear, distortion or dam ­
age.
6. Case halves for damaged or warped mating sur­
faces* cracks, porosity, or damaged threaded holes.
7. Synchronizer stop ring for cracks, chips, spalling, or
excessive wear.
8. Synchronizer hub and sleeve for cracks, chips,
spalling, or excessive wear.
9. Pads on the mode fork and the range fork for wear,
distortion.
10. Oil pump gears and case halves for wear, spalling,
cracks, and damage. Replace complete assem bly if
there is wear.
11. Input gear, planetary carrier and range shift hub
tooth cham fers for excessive wear.