For 1990-2009 cars

### Clutch Housing

1. Clean the clutch housing in a suitable solvent and air dry.
2. Inspect the clutch housing for the following conditions:

• | Cracks

• | Damaged mounting flanges

• | Damaged bolt holes

### Front Case

1. Clean the front case in a suitable cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution in the Preface section.

2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Inspect the input shaft bearing bore (a) for the following conditions:

• | A spun bearing

• | Cracks

5. Inspect the countershaft front bearing bore (b) for the following conditions:

• | A spun bearing

• | Cracks

6. Replace the case assembly if any of the above conditions are found. The front case is only serviced with the intermediate case.
7. Inspect the sealing surfaces for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the case threaded bolt holes for damage.
10. Repair any damaged threads.
11. Inspect the location pins (72) for being loose or missing.
12. Repair or replace any damaged location pins.
13. Inspect the shift shaft bushings (295) for excessive wear.
14. Replace the case assembly if the shift shaft bushings (295) are faulty.
15. Inspect the shift shaft bushing plugs (63 and 64) for leaking or damage.
16. Replace the plugs if faulty. Refer to Transmission Case Disassemble and Transmission Case Assemble.

### Extension Housing 4WD

1. Clean the extension housing in a suitable cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution in the Preface section.

2. Remove the sealer from the extension sealing surfaces.
3. Inspect the extension for being broken or cracked.
4. Inspect the transfer case mounting surface (a) for damage.
5. Inspect the sealing surfaces for damage.
6. Repair small scratches or nicks with a soft stone.
7. Inspect the extension threaded bolt holes for damage.
8. Repair any damaged threads.
9. Replace the extension if the above damages can not be repaired.
10. Inspect the shift control housing location pins (523) for being loose or missing.
11. Repair or replace any damaged location pins.
12. Inspect the shift shaft bushings (297) for excessive wear.
13. Replace the extension housing if the shift shaft bushings (297) are faulty.
14. Inspect the shift shaft plug (65) for leaking or damage.
15. Replace the shift shaft plug if faulty. Refer to Transmission Extension Disassemble and Transmission Extension Assemble.
16. Inspect the reverse control lever restriction operation for the following conditions:

• | Moves in and out

• | Rotates

17. Replace the reverse control lever restriction if faulty. Refer to Transmission Extension Disassemble and Transmission Extension Assemble.

### Extension Housing RWD

1. Clean the extension housing in a suitable cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution in the Preface section.

2. Remove the sealer from the extension sealing surfaces.
3. Inspect the extension for being broken or cracked.
4. Inspect the rear bushing (6) for wear or damage. The bushing is serviced only with the extension housing.
5. Inspect the shift shaft bushings (297) for excessive wear.
6. Replace the extension if any of the above conditions are found.
7. Inspect the sealing surfaces for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the case threaded bolt holes for damage.
10. Repair any damaged threads.
11. Inspect the shift control housing location pins (523) for being loose or missing.
12. Repair or replace any damaged location pins.
13. Inspect the reverse control lever restriction operation for the following conditions:

• | Moves in and out

• | Rotates

14. Replace the reverse control lever restriction if faulty. Refer to Transmission Extension Disassemble and Transmission Extension Assemble.

### Intermediate Case

1. Clean the intermediate case in a suitable cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution in the Preface section.

2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Inspect the output shaft bearing bore (a) for the following conditions:

• | A spun bearing

• | Cracks

5. Inspect the countershaft rear bearing bore (b) for the following conditions:

• | A spun bearing

• | Cracks

6. Inspect the shift shaft bushings (296) for excessive wear.
7. Replace the intermediate case if any of the above conditions are found. The intermediate case is only serviced with the front case.
8. Inspect the sealing surfaces for damage.
9. Repair small scratches or nicks with a soft stone.
10. Inspect the case threaded bolt holes for damage.
11. Repair any damaged threads.
12. Inspect the location pins (71 and 72) for being loose or missing.
13. Repair or replace any damaged location pins.

### Input Shaft Bearing Retainer

1. Clean the input shaft bearing retainer in a suitable cleaning solvent and air dry.

Caution: Refer to Machined Surface Damage Caution in the Preface section.

2. Remove the sealer from the retainer sealing surfaces.
3. Inspect the bearing retainer for being broken or cracked.
4. Replace the bearing retainer if any of the above conditions are found.
5. Inspect the sealing surfaces for damage.
6. Repair small scratches or nicks with a soft stone.