GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • DT-47752 Split Plate Set
    • J-2619-A Slide Hammer w/Adapter
    • J 8107-2 Side Bearing Puller Pilot
    • J 8433 Two Jaw Puller
    • J 22888-20A Universal Two Jaw Puller
    • J 23444-A Extreme Press Lubricant - 1/4-Ounce Tube
    • J 29369-1 Bushing and Bearing Remover

    Object Number: 1309861  Size: SH
  1. Remove the bolts (16) and the dampener (300), some models.

  2. Object Number: 925580  Size: SH
  3. Remove the drain plug (8) and the fill plug (6). Ensure all transfer case fluid is drained out of the transfer case.

  4. Object Number: 925591  Size: SH

    Notice: Clean all exposed bolt threads prior to removing the bolts. Failure to clean the exposed bolt threads prior to removal may result in bolt thread damage.

  5. Remove the 17 case attaching bolts (11).
  6. Notice: Refer to Machined Surface Damage Notice in the Preface section.


    Object Number: 925593  Size: SH
  7. Using a screwdriver at the pry points located on the case (1) and cover (2), pry the case (1) and cover (2) apart.

  8. Object Number: 1463992  Size: SH
  9. Separate the case (1) and cover (2).
  10. Remove the alignment dowel (3) from the case, if necessary.

  11. Object Number: 1523365  Size: SH
  12. Remove the chain snubber.

  13. Object Number: 1523372  Size: SH
  14. Install 1 plate of the DT-47752 perpendicular to the chain and rotate 180 degrees.

  15. Object Number: 1523378  Size: SH
  16. Install the second plate perpendicular to the chain and secure with the short plate bolts.

  17. Object Number: 1523382  Size: SH
  18. Install the DT-47752-2 (2) onto the front output shaft (112).
  19. Important: Use high pressure grease J 23444-A on the screw threads.

  20. Using the long bolts and washers from the DT-47752 , install the J 8433  (1). Tighten evenly so the puller remains parallel to the plates.

  21. Object Number: 1523393  Size: SH

    Notice: Failure to support the input shaft and carrier during removal may bind and damage the chain.

  22. Install the DT-47752-3 into the input shaft.
  23. Using an impact wrench, tighten the forcing screw of the DT-47752-2 in order to remove the sprockets, chain, and carrier assembly.

  24. Object Number: 1523382  Size: SH
  25. Remove the J 8433  (1) and the DT-47752-2 (2).

  26. Object Number: 1523394  Size: SH

    Important: If the chain and sprockets are to be used again, note the position of the blue chain link, in or out.

  27. Remove the lower sprocket (112), chain (109), and carrier (111) as an assembly.

  28. Object Number: 1523395  Size: SH
  29. Remove the DT-47752 from the case.

  30. Object Number: 925596  Size: SH
  31. Remove the snap ring (114).
  32. Push the front output shaft (112) from the case (1).

  33. Object Number: 1523396  Size: SH
  34. Remove the vent baffle bolt (9) and baffle (10) from the case (1).
  35. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 925601  Size: SH
  36. Using a hammer and a suitable driver, remove the front output seal (13) and input seal (14) from the case (1).

  37. Object Number: 925603  Size: SH

    Important: Only remove the bearings if they are to be replaced.

  38. Using a hammer and a suitable punch, remove the front output bearing (113) and input bearing (117) if they are to be replaced.

  39. Object Number: 925605  Size: SH
  40. If required, remove the vent (15) and discard.
  41. Install a NEW vent.

  42. Object Number: 1532898  Size: SH
  43. Remove the thrust washer (100) from the carrier (111).

  44. Object Number: 1463964  Size: SH
  45. Using a press, remove the input shaft assembly (118, 107, and 110) from the carrier (111).

  46. Object Number: 1523388  Size: SH

    Important: The carrier assembly (111) must be installed with the thrust washer and groove around the splines toward the output shaft. Reversing this causes a mis-build, and the wrong torque split of 60/40.

  47. Note the direction of the carrier assembly (111). The groove around the splines face toward the output shaft.

  48. Object Number: 1463973  Size: SH
  49. Using the J 22888-20A  (1) and the J 8107-2  (2), remove the rear sun gear (101) from the rear output shaft.

  50. Object Number: 925628  Size: SH
  51. Using snap ring pliers, remove the snap ring (102) from the output shaft (106).
  52. Push the output shaft (106) from the cover (2).
  53. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.

    Notice: Refer to Transfer Case Bearing Removal Notice in the Preface section.


    Object Number: 925631  Size: SH
  54. Using a hammer and a suitable punch, from inside the cover, drive out the rear output seal (7) and the outside output bearing (104).
  55. Notice: Refer to Transfer Case Bearing Removal Notice in the Preface section.


    Object Number: 925633  Size: SH
  56. Using a hammer and a suitable punch, from outside the cover (2), inside the output shaft bore, drive out the inner output shaft bearing (103).
  57. Notice: Refer to Transfer Case Bearing Removal Notice in the Preface section.


    Object Number: 925634  Size: SH
  58. Using the J-2619-A  (1) and the J 29369-1  (2), remove the front output cover bearing (116) from the cover.