Q about worn AWD clutch baskets

[CNY_Dave]

I'm going to swap the AWD solenoid in my '04 trans for an '03 solenoid to make the AWD compatable with my '03 TCU.

That is assuming the passages in the trans case are the same. If the valve and/or valve plate is different I can swap the whole valve/plate.

 

Long story short, in '04 the signal to the solenoid was reversed. To 'get by' I built a small circuit that would invert the signal to get my AWD working. It doesn't work quite right, and I do not know if the sudden late engagement clunk (heh, BANG) engagement and the surging I feel during periods of near full throttle are because a merely inverted signal is not quite right, or if the clutch basket(s) is/are grooved.

 

I recall reading a late heavy engagement as a symptom of grooving, but not of having the AWD surge while at heavy throttle. (goes away with the FWD fuse so I know it's the MPT clutch).

 

 

ANYWAY, is it normally the inner or outer basket that grooves?

 

Can I swap over my other whole AWD clutch assembly without having measure the assembly and tailcase and adjusting/buying shims?

 

If just the inner basket wears and mine is grooved, am I better off swapping just the front shaft or the entire assembly?

 

Is the shimming done to account for just the tailhousing machining, or that and the clutch disks, or all the components?

[CNY_Dave]

I have seen lots a pics of inner basket wear, haven't seen any of the outer basket.