Express 3500 V8-6.0L VIN U (2004)
1. Clean the rear output shaft with rear output shaft bearing in cleaning solvent.
2. Air dry and ensure all solvent is removed from the bearing.
3. Inspect the speed reluctor wheel for damage.
4. Replace the speed reluctor wheel if it is faulty.
5. Inspect the rear output shaft bearing for the following conditions:
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Scoring
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Pitting
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Brinneling
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Excessive wear
6. Replace the rear output shaft bearing if it is faulty.
7. Inspect the mainshaft rear support bushing for the following conditions:
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Pitted
^
Wear
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Corrosion
8. Replace the mainshaft rear support bushing if any of the above conditions are found.
9. Inspect the rear output shaft splines for wear or damage.
10. Inspect the rear output shaft bearing area for a spun bearing.
11. Replace the rear output shaft if any of the above conditions are found.
Shift System Components
1. Clean the following shift system components in cleaning solvent and air dry.
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The lockup mode shift fork (1)
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The high/low range shift fork (2)
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The shift detent lever shaft assembly (3)
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The shift fork spring (4)
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The shift fork shaft (5)
2. Inspect the shift fork shaft (5) for straightness and excessive wear at the shift fork locations.
3. Replace the shift fork shaft if it is not straight or if it is worn excessively.
