GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 2619-01 Slide Hammer
    • J 3289-20 Holding Fixture
    • J 22912-B Split-Plate Bearing Puller
    • J 23907 Slide Hammer with Bearing Adapter
    • J 26941 Bushing and Bearing Remover - 3-4 in
    • J 45380 Transfer Case Rear Bushing Remover and Installer
    • J 45548 Mainshaft Support Bushing/Bearing Remover
    • J 45759 Assembly Fixture

    Object Number: 824069  Size: SH
  1. Attach the J 45759 to the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 .

  2. Object Number: 819573  Size: SH
  3. Mount the J 3289-20  (1) to a sturdy workbench.
  4. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.

  5. Object Number: 740284  Size: SH
  6. Remove the access plug from the transfer case.

  7. Object Number: 662047  Size: SH
  8. Remove the transfer case vehicle speed sensor.
  9. Remove the plastic vent from the case; a NEW aluminum vent must be installed during assembly.
  10. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 678215  Size: SH
  11. Remove the input shaft seal.

  12. Object Number: 715670  Size: SH
  13. Remove the rear output shaft seal.

  14. Object Number: 801274  Size: SH
  15. Inspect the rear output shaft bushing for scoring or wear.
  16. Using the J 45380 , remove the rear output shaft bushing.
  17. • Install the finger section of the J 45380 in front of the bushing.
    • Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
    • Using a wrench on the forcing screw, remove the rear output shaft bushing.

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


    Object Number: 749439  Size: SH
  18. Insert a flat-tipped screwdriver in the inner race.
  19. Pry the inner race back.

  20. Object Number: 749435  Size: SH
  21. Insert a small pry bar in the inner race.

  22. Object Number: 749436  Size: SH
  23. Remove the inner race from the seal.

  24. Object Number: 749437  Size: SH
  25. Insert a flat-tipped screwdriver or a small pry bar between the lip of the outer lip of the front output shaft seal and the transfer case.

  26. Object Number: 749438  Size: SH
  27. Remove the remaining part of the front output shaft from the transfer case.

  28. Object Number: 740281  Size: SH

    Important: Mark the location of the brackets.

  29. Remove the transfer case bolts, washers, and brackets.

  30. Object Number: 695581  Size: SH
  31. Insert a flat-bladed screwdriver in the slot on the left side of the transfer case.

  32. Object Number: 695583  Size: SH
  33. Insert a flat-bladed screwdriver in the slot on the right side if the transfer case.
  34. With equal pressure, press down on the screwdrivers.

  35. Object Number: 649760  Size: SH
  36. Insert a pair of snap ring pliers into the slot.
  37. Using the snap ring pliers, open the outer rear output shaft bearing retaining ring.

  38. Object Number: 740278  Size: SH
  39. Remove the rear case half from the front case half.

  40. Object Number: 729396  Size: SH
  41. Remove the oil pump screen assembly.

  42. Object Number: 729398  Size: SH
  43. Remove the rear output shaft assembly. Hold the planetary carrier in place to prevent removing it with the rear output shaft.

  44. Object Number: 729399  Size: SH
  45. Remove the rear output shaft bearing retaining ring.

  46. Object Number: 729521  Size: SH
  47. Using the flat side of the J 22912-B and a press, remove the rear output shaft bearing.

  48. Object Number: 718721  Size: SH

    Important: Move the oil pump retaining ring down and away from the tone wheel. This ensures that the J 22912-B does not get caught on the retaining ring.

  49. Using the J 22912-B and a press, remove the speed reluctor wheel.
  50. Discard the speed reluctor wheel after removal.

  51. Object Number: 729400  Size: SH
  52. Remove the oil pump retaining ring.

  53. Object Number: 729402  Size: SH
  54. Remove the oil pump assembly.

  55. Object Number: 729405  Size: SH
  56. Using a flat-bladed screwdriver, unseat the annulus retaining ring.

  57. Object Number: 729414  Size: SH
  58. Remove the annulus gear retaining ring.

  59. Object Number: 729416  Size: SH
  60. Remove the rear output shaft.

  61. Object Number: 805665  Size: SH
  62. Inspect the mainshaft rear bearing in the rear output shaft for being faulty. Refer to Transfer Case Cleaning and Inspection .
  63. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear bearing.

  64. Object Number: 729417  Size: SH
  65. Remove the planetary carrier assembly. Tap on the end of the mainshaft with a soft-face hammer while lifting off the planetary carrier. A spring style retaining ring holds the planetary carrier to the mainshaft.

  66. Object Number: 729418  Size: SH
  67. Remove the planetary carrier assembly thrust washer.

  68. Object Number: 729419  Size: SH
  69. Remove the sun gear.

  70. Object Number: 729534  Size: SH
  71. Remove the carrier retaining ring.

  72. Object Number: 729522  Size: SH
  73. Remove the mainshaft.

  74. Object Number: 729423  Size: SH
  75. Remove the planetary carrier sun gear bearing.

  76. Object Number: 729562  Size: SH
  77. Remove the driven sprocket retaining ring.

  78. Object Number: 729532  Size: SH
  79. Remove the drive chain assembly.

  80. Object Number: 729424  Size: SH
  81. Remove the viscous coupling.

  82. Object Number: 729425  Size: SH
  83. Using a flat-bladed screwdriver, remove the input gear bearing retaining ring from the groove.

  84. Object Number: 729426  Size: SH
  85. Remove the input gear bearing retaining ring.

  86. Object Number: 729518  Size: SH
  87. Remove the input gear assembly.

  88. Object Number: 701641  Size: SH
  89. Remove the input gear bearing retaining ring.

  90. Object Number: 729523  Size: SH
  91. Using a press, remove the input bearing.

  92. Object Number: 805641  Size: SH
  93. Remove the front output shaft bearing retaining ring.

  94. Object Number: 724388  Size: SH
  95. Remove the front output shaft assembly.

  96. Object Number: 164528  Size: SH
  97. Remove the front output shaft bearing retainer ring.

  98. Object Number: 164524  Size: SH
  99. Remove the front output shaft bearing.

  100. Object Number: 801288  Size: SH
  101. Inspect the front output shaft rear bearing. Refer to Transfer Case Cleaning and Inspection .
  102. Using the J 23907  (2) and the J 26941  (1), remove the front output shaft bearing from the rear case.