Express 3500 V8-6.0L VIN U (2004)
1. Clean the front case half in cleaning solvent and air dry.
2. Remove the metal shavings from the case half bolt holes.
Notice: Refer to Machined Surface Damage Notice in Service Precautions.
3. Remove the sealer from the case sealing surfaces.
4. Inspect the case for being broken or cracked.
5. Inspect the front output shaft front bearing bore (5) for the following conditions:
^
A spun bearing
^
Cracks
6. Inspect the input shaft bearing bore (4) for the following conditions:
^
A spun bearing
^
Cracks
7. Replace the front case half if any of the above conditions are found.
8. Inspect the sealing surfaces (1) for damage.
9. Repair small scratches or nicks with a soft stone.
10. Inspect the front case to transmission case mounting surface for damage.
11. Inspect the case threaded bolt holes (2) for damage.
12. Repair any damaged threads.
13. Inspect the transmission to transfer case studs for damage.
14. Replace any damaged studs. Refer to Transfer Case Disassemble and Transfer Case Assemble.
15. Inspect the location pins (3) for being loose or missing.
16. Repair or replace any damaged location pins.
17. Inspect the front output shaft front bearing and the input shaft bearing for the following conditions:
^
Roughness
^
Brinelling
^
Pitting
18. Replace the bearings if any of the above conditions are found.
Rear Case Half
1. Clean the rear case half in cleaning solvent and air dry.
