Rear Output Drive Housing Cleaning and Inspection

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Rear Output Drive Housing Components

Courtesy of SUZUKI OF AMERICA CORP.

CALLOUT AND COMPONENT NAME TABLE

Callout	Component Name
Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry. The transfer case rear output drive housing is not serviced. If damage cannot be repaired, the transfer case must be replaced.
1	Transfer Case Rear Output Shaft Flange Replace if flange, threaded holes, or splines are damaged. Inspect sealing surface for corrosion, excessive wear, or damage.
2	Transfer Case Rear Output Shaft Oil Slinger Tip: Replace the slinger if damaged, cracked, loose, or distorted.
3	Transfer Case Rear Output Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting.
4	Transfer Case Rear Output Shaft Housing Inspect for cracks, broken areas, or other damage. Inspect bearing races for roughness, brinelling, or pitting. Inspect the O-ring channel for porosity or damage. Scratches or nicks in other areas may be repaired with light sanding.
5	Transfer Case Rear Output Shaft Splines Tip: Inspect for damage and press fit to flange.
6	Transfer Case Rear Output Shaft Tip: Inspect for pitting, excessive wear, or damage.