1

Transfer Case Coil Assembly

2

Transfer Case Coil Nuts (Qty: 3)

3

Transfer Case Coil Connector Assembly

4

Transfer Case Clip

5

Transfer Case Clutch Coil Harness Protector

Tip
Install common tie wraps to secure the harness protector and seat the wire in the wire clip.

1

Transfer Case Front Output Shaft Drive Chain Snubber

2

Transfer Case Front Output Shaft Drive Chain Snubber Bolts (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

Tip

Tighten
7 N·m (62 lb in)

3

Transfer Case Vent Baffle

4

Transfer Case Vent Baffle Bolt (Qty: 1)

Tip

Tighten
7 N·m (62 lb in)

1

Transfer Case Front Output Shaft Seal Dirt Deflector

Tip
Replace only if removed or damaged.

2

Transfer Case Front Output Shaft

3

Transfer Case Front Output Shaft Driven Sprocket Spacer

4

Transfer Case Input Shaft Assembly

5

Transfer Case Oil Pump Assembly

Tip

6

Transfer Case Oil Pump Suction Hose Clamp

7

Transfer Case Oil Pump Suction Hose Bolt

Caution: Refer to Fastener Caution in the Preface section.

Tighten
7 N·m (62 lb in)

8

Transfer Case Front Output Shaft Drive Sprocket Thrust Washer

9

Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly

10

Transfer Case Front Output Shaft Drive Sprocket Thrust Washer

11

Transfer Case Front Output Shaft Drive Chain Assembly

Procedure:

Install the drive chain assembly, transfer case front output shaft drive sprocket, and the transfer case front output shaft driven sprocket simultaneously.

Tip

1

Transfer Case Front Output Shaft Drive Sprocket Spacer

2

Transfer Case Clutch Pack Assembly and Armature

Tip

3

Transfer Case Snap Ring

4

Transfer Case Wave Spring

5

Transfer Case Apply Cam

6

Transfer Case Balls

7

Transfer Case Rotor Assembly

8

Transfer Case Thrust Bearing

9

Transfer Case Thrust Washer

Tip
Always verify that the correct thrust washer is installed for proper clutch end-play. Replacement of internal components will alter the end-play. Refer to Four Wheel Drive Clutch Shim Selection.

1

Transfer Case - Rear Half

Tip
Apply a 3.175 mm (1/8 in) bead of room temperature vulcanizing (RTV) sealant, or equivalent, to the mating surface of the cover.

2

Transfer Case Half Bolt

Caution: Refer to Fastener Caution in the Preface section.

Tip
The bolts are self-tapping and must be hand started. Do not use power-assisted tools to install the bolts.

Tighten
27-35 N·m (20-26 lb in)

3

Transfer Case Location Pin - If Removed

4

Transfer Case Front Output Shaft Bearing Retaining Ring

5

Transfer Case O-Ring Seal

Tip
If the seal is removed, replace with a NEW seal.

6

Transfer Case Front Output Shaft Hole Plug

Tighten
15-20 N·m (11-14 lb ft)

1

Transfer Case Rear Output Shaft Seal Dirt Deflector

Tip
Replace only if removed or damaged.

2

Transfer Case Rear Output Shaft Flange Assembly

3

Transfer Case Rear Output Shaft Flange O-Ring Seal

4

Transfer Case Rear Output Shaft Thrust Washer

5

Transfer Case Rear Output Shaft Flange Nut

Caution: Refer to Fastener Caution in the Preface section.

Tighten
305-332 N·m (225-245 lb ft)

Special Tools

DT-48847 Pinion Flange Holder

6

Transfer Case Vibration Dampener

7

Transfer Case Vibration Dampener Bolt

Tighten
27-35 N·m (20-26 lb ft)

1

Transfer Case Temperature Sensor Assembly

2

Transfer Case Oil Drain Plug - Magnetic

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

Tip
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the drain plug before installation.

Tighten
19-30 N·m (14-22 lb ft)

3

Transfer Case Oil Fill Plug

Tip

Tighten
19-30 N·m (14-22 lb ft)

4

Transfer Case Vent Assembly