1

Transfer Case Input Shaft

2

Transfer Case Wave Washer

Tip
A small amount of Transjel Lubricant may be used to hold in place.

3

Transfer Case Input Shaft Thrust Bearing Washer

4

Front/Rear Drive Differential Carrier Assembly

1

Transfer Case Two/Four Wheel Drive Chain, Front Output Shaft Drive Sprocket and Two/Four Wheel Drive Driven Sprocket Assembly

Tip

2

Transfer Case Rear Output Shaft

1

Transfer Case Chip Collector Magnet

2

Transfer Case Oil Pump Suction Pipe O-Ring Seal

Tip
Lightly lubricate the O-ring seal with clean Auto Trak II.

3

Transfer Case Oil Pump Suction Pipe

4

Transfer Case Oil Pump Hose

5

Transfer Case Oil Pump Screen

1

Sealer GM P/N 12345739 (Canadian P/N 10953541), or Equivalent

Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

Procedure

1. Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.
2. Apply a 2 mm (0.078 in) bead of sealant to the front half case.

2

Transfer Case Rear Case Half

3

Transfer Case Mainshaft Side Bracket

4

Transfer Case Front Shaft Side Bracket

5

Transfer Case Bolts (Qty: 23)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
22 N·m (16 lb ft)

1

Transfer Case Oil Pump Drive Gear

2

Transfer Case Oil Pump Driven Gear

3

Transfer Case Oil Pump Cover

4

Transfer Case Oil Pump Cover Bolts (Qty: 6)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
11 N·m (97 lb in)

5

Transfer Case Rear Output Shaft Speed Reluctor Wheel

Tip

Special Tools

J 45235 Speed Sensor Reluctor Wheel Installer - Rear

6

Sealer GM P/N 12345739 (Canadian P/N 10953541), or Equivalent

Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

Procedure

1. Ensure both sealing surfaces of the transfer case rear output shaft rear bearing retainer assembly and rear half case are free of dirt, oil, and cleaning solvent.
2. Apply a 2 mm (0.078 in) bead of sealer to the retainer assembly.

7

Transfer Case Rear Output Shaft Rear Bearing Retainer Assembly

8

Transfer Case Bolts (Qty: 23)

Tighten
22 N·m (16 lb ft)

1

Transfer Case Extension Bushing

Tip
If the bushing was removed, a new bushing must be installed.

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

Tip

1. Install the bushing on the finger section of the J 45380 .
2. Install the finger section to the main body of the J 45380 .
3. Position the bushing and tool to the retainer assembly.
4. Install the bushing until the tool bottoms on the retainer assembly.

2

Transfer Case Rear Output Shaft Seal

Tip

1. Align the notch on the J 37668-A with the tab on the seal.
2. Install the seal with the tab at the top and the weep hole at the bottom.

Special Tools

J 37668-A Output Shaft Seal Installer

1

Vehicle Speed Sensor O-Ring

Tip
Lightly lubricate the O-ring with clean Auto Trak II.

2

Vehicle Speed Sensor

Notice: Refer to Component Fastener Tightening Notice in the Preface section.

Tighten
17 N·m (13 lb ft)

3

Transfer Case Oil Fill Plug

Tighten
27 N·m (20 lb ft)

4

Transfer Case Oil Drain Plug

Tighten
27 N·m (20 lb ft)

5

Transfer Case Vent Pipe

Tip
Apply retaining compound GM P/N 12377901 (Canadian P/N 10953504) to the vent pipe before installation.

1

Transfer Case Input Shaft Seal

Special Tools

J 42738 Seal Installer

2

Transfer Case Front Output Shaft Seal

Special Tools

3

Transfer Case Assembly

Tip
Remove from J 3289-20 and remove the J 45759 from the transfer case.