GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 3289-20 Holding Fixture
    • J 8092 Driver Handle
    • J 8092 Universal Handle
    • J 22873 Mainshaft Bushing Installer
    • J 36370 Drive Sprocket Needle Bearing Installer
    • J 36850 Transjel Lubricant
    • J 37668-A Seal Installer
    • J 42738 Seal Installer
    • J 43484 Seal Installer
    • J 44295 Clutch Pack Shimming Kit
    • J 45239 Needle Bearing Installer
    • J 45380 Transfer Case Rear Bushing Remover and Installer
    • J 45383 Input Gear Pilot Bearing Installer
    • J 45759 Assembly Fixture

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 165657  Size: SH

    Important: 

       • When installing the new retaining rings in any of the following service procedures, ensure that the retaining rings are properly seated before proceeding to the next service procedure. Always use NEW retaining rings.
       • The front output shaft seal and the input shaft seal only require replacement if faulty, or if removing the front output shaft or input gear.

  1. If removed, install the transfer case mounting studs to the height of 29.5 mm-30.5 mm (1.16-1.20 in).

  2. Object Number: 819573  Size: SH
  3. Attach the J 45759 to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759 .
  4. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin.

  5. Object Number: 712123  Size: SH

    Important: Use only new retaining rings.

  6. Install the input bearing. The cage side of the bearing faces to the case front.

  7. Object Number: 712116  Size: SH
  8. Install the input bearing retaining ring.

  9. Object Number: 801287  Size: SH
  10. Install the front output shaft front bearing. The cage side of the bearing faces to the front of the case.
  11. Install the front output shaft front bearing retaining ring.

  12. Object Number: 801306  Size: SH
  13. Using the J 8092  (1) and the J 36370  (2), install the front output shaft rear bearing.
  14. • The lettering on the bearing faces toward the tool.
    • Use the double shoulder side of the J 36370 to install the bearing recessed in the bore.

    Object Number: 857325  Size: SH
  15. Using the J 45239  (2) and J 8092  (1), install the control actuator lever shaft bearing. The seal on the bearing faces outward.

  16. Object Number: 857316  Size: SH
  17. Using transfer case fluid, lubricate the control actuator lever shaft bearing.
  18. Install the control actuator lever shaft.

  19. Object Number: 857315  Size: SH
  20. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.

  21. Object Number: 804160  Size: SH
  22. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver.
  23. The installed depth of the cup plug is 26.75 mm (1.05 in) from the end of the shaft.


    Object Number: 801292  Size: SH
  24. Using the J 22873 and a hydraulic press, install a NEW tone wheel on the front output shaft.

  25. Object Number: 165272  Size: SH
  26. Install the front output shaft assembly. Use a soft-face hammer to tap the front output shaft into the bearing.

  27. Object Number: 717108  Size: SH
  28. Install the front output shaft retaining ring.

  29. Object Number: 857314  Size: SH

    Important: Depending on the version of the transfer case, it may have either a 4 pinion gear or 6 pinion gear planetary carrier assembly. The 4 pinion gear planetary carrier is used with transmission RPO M30 and the input gear splines are 27 teeth. The 6 pinion gear planetary carrier is used with transmission RPO MT1 and MN8 and the input gear splines are 32 teeth. The repair procedures are the same for both planetary carriers.

  30. Lubricate the thrust washer for the input shaft with J 36850 or equivalent.
  31. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.

  32. Object Number: 801303  Size: SH
  33. Using the J 8092  (1) and the J 45383  (2), install the pilot bearing in the input shaft.

  34. Object Number: 165294  Size: SH
  35. Install the input shaft assembly.

  36. Object Number: 857313  Size: SH
  37. Lubricate the input shaft thrust washer with J 36850 or equivalent.
  38. Install the input shaft thrust washer.

  39. Object Number: 165308  Size: SH
  40. Lubricate the carrier lock plate with J 36850 or equivalent.
  41. Install the carrier lock plate.

  42. Object Number: 165318  Size: SH
  43. Install the retaining ring for the planetary gear shaft.

  44. Object Number: 165341  Size: SH
  45. Install the planetary gear carrier. Use a soft-face hammer to tap the input shaft into the bearing.

  46. Object Number: 164463  Size: SH
  47. Install the outer retaining ring for the input gear bearing.

  48. Object Number: 801284  Size: SH
  49. Install new shift fork pads, if removed.
  50. Install the range shift sleeve in the range fork.

  51. Object Number: 561742  Size: SH
  52. Align the range shift sleeve on the planetary carrier.
  53. Align the roller on the range fork in the control actuator lever slot.
  54. Install the range shift fork.

  55. Object Number: 165035  Size: SH
  56. Install the shift fork shaft.

  57. Object Number: 701627  Size: SH
  58. Install the clutch lever assembly.

  59. Object Number: 164482  Size: SH

    Important: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.

  60. Install new O-ring seals on the clutch lever pivot pins.
  61. Lubricate the O-ring seals with transfer case fluid.
  62. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the clutch lever pivot pin threads.
  63. Notice: Refer to Fastener Notice in the Preface section.

  64. Install the clutch lever pivot pins with the aluminum washers and O-ring seals in the front case half.
  65. Tighten
    Tighten the clutch lever pivot pins to 61 N·m (45 lb ft).


    Object Number: 164507  Size: SH

    Important: The following service procedure is to be performed only if the rear output shaft is new.

  66. Install the rear output shaft oil restrictor flush with the end of the shaft.

  67. Object Number: 857326  Size: SH

    Important: In order to position the bearing at the proper depth, ensure that the double shoulder of the J 36370 is against the bearing.

  68. Using the J 8092  (1) and the J 36370  (2), install the clutch housing bearing.

  69. Object Number: 695496  Size: SH
  70. Clamp the rear output shaft in a soft-jaw vise with the front end facing up.
  71. Install the clutch housing on the rear output shaft.

  72. Object Number: 695500  Size: SH
  73. Install the clutch hub.

  74. Object Number: 857312  Size: SH
  75. Install the clutch hub oil restrictor plate.

  76. Object Number: 707041  Size: SH
  77. Install the clutch pressure plate inner in the clutch housing, with the notch in the plate facing down.

  78. Object Number: 670237  Size: SH
  79. Install a friction clutch pressure plate.
  80. Install a steel clutch pressure plate.
  81. Continue to install the friction and the steel clutch plates, alternating until 10 friction plates and 9 steel plates are installed.

  82. Object Number: 857310  Size: SH
  83. Install the clutch hub retaining ring. Push down on the oil restrictor plate.

  84. Object Number: 632475  Size: SH

    Important: A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload can cause driveability concerns and failure of the transfer case.

  85. Securely install the base plate (3) of the J 44295 in a vise with the machined surface of the locating tabs facing up.
  86. Install the assembled rear output shaft with the clutch housing, the inner clutch plates, and the outer clutch plates on the base plate (3) of the J 44295 .
  87. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
  88. Place the gage block (2) of the J 44295 on 1 of the locating tabs of the base plate (3) of the J 44295 .
  89. Using a feeler gage, measure between the gage block (2) and the weight (1) of the J 44295 .
  90. Measure with the gage block (2) and the feeler gage on the remaining 2 locating tabs of the base plate (3).
  91. Important: The specification is the average clearance remaining between the weight (1) and the gage block (2).

  92. The average of the 3 measurements is the required shim thickness.
  93. Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.

  94. Select from the clutch plate shim package the correct shim or shims plus or minus 0.10 mm (0.004 in). You may use a combination of 2 shims to obtain the correct thickness.
  95. The shims in the clutch plate shim package are the following thickness:

    • 0.30 mm (0.12 in)
    • 0.56 mm (0.022 in)
    • 0.81 mm (0.032 in)
    • 1.04 mm (0.041 in)
    • 1.30 mm (0.051 in)
    • 1.55 mm (0.061 in)
    • 1.80 mm (0.071 in)
    • 2.08 mm (0.081 in)
  96. Remove the weight (1) of the J 44295 .
  97. Important: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then install the clutch plates again, it could change the measurement.

  98. Install the shim or shims.

  99. Object Number: 801305  Size: SH
  100. Using a suitable press plate and a hydraulic press, press the clutch bearing inner support in the clutch apply plate bearing. Ensure the bearing inner bearing race is supported.

  101. Object Number: 2040336  Size: SH
  102. Install the clutch apply plate bearing and inner support in the clutch apply plate.

  103. Object Number: 857309  Size: SH
  104. Install the clutch pressure plate spring.
  105. Align the tabs on the clutch pressure plate with the grooves in the clutch hub and install the clutch pressure plate assembly.

  106. Object Number: 164262  Size: SH
  107. Install the clutch apply plate retaining ring. Push down on the apply plate to access the retaining ring groove.

  108. Object Number: 164247  Size: SH
  109. Align the tab on the clutch inner support bearing hub with the clutch lever.
  110. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
  111. Install the rear output shaft assembly.

  112. Object Number: 163905  Size: SH

    Important: Ensure to align the marks of the drive chain and sprockets if using the chain and sprockets again.

  113. Install the drive chain and sprockets. The blue chain links must face up or toward the rear of the vehicle.

  114. Object Number: 701617  Size: SH
  115. Install the drive sprocket retaining ring.

  116. Object Number: 857307  Size: SH
  117. Install the driven sprocket retaining ring.

  118. Object Number: 163888  Size: SH
  119. Install a new oil pump suction pipe O-ring in the oil pump.

  120. Object Number: 886580  Size: SH
  121. Install the oil pump assembly.
  122. Install the oil pump wave spring.

  123. Object Number: 163872  Size: SH
  124. Install the oil pump screen.
  125. Install the connector on the oil pump screen.
  126. Install the oil pump suction pipe to the oil pump.
  127. Connect the oil pump suction pipe to the connector.

  128. Object Number: 163856  Size: SH
  129. Install the transfer case magnet.

  130. Object Number: 701592  Size: SH
  131. Install the rear output shaft speed reluctor wheel.

  132. Object Number: 701589  Size: SH

    Important: Install the rear output shaft bearing with the groove for the retaining ring facing up.

  133. Install the rear output shaft bearing.

  134. Object Number: 701586  Size: SH
  135. Install the rear output shaft bearing retaining ring. Push down on the rear output shaft bearing to compress the oil pump wave spring.

  136. Object Number: 724251  Size: SH
  137. Remove the 1st design oil pump wear sleeve from the rear case half.

  138. Object Number: 1868938  Size: SH

    Important: Ensure the oil pump wear sleeve is properly positioned to the largest lug of the oil pump.

  139. Install the 2nd design oil pump wear sleeve (1) to the oil pump (2).

  140. Object Number: 163815  Size: SH

    Important: Ensure the locating pins are installed in the front case half.

  141. Install the locating pins in the front case, if necessary.

  142. Object Number: 698077  Size: SH

    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.

    Important: Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.

  143. Apply a 3 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.

  144. Object Number: 163737  Size: SH
  145. Align the outside retaining ring for the rear output shaft bearing so that it is easily accessed through the opening in the rear case half.
  146. Lower the rear case half in to place.

  147. Object Number: 649760  Size: SH
  148. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing.
  149. Insert a rubber coated screwdriver into 1 of the speed sensor holes and lift up on the speed reluctor wheel, then seat the retaining ring.

  150. Object Number: 163733  Size: SH

    Notice: This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. New nylon coated case bolts and aluminum washers must be used. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.

  151. Install the new case bolts, washers, and brackets.
  152. Tighten
    Tighten the case bolts to 37 N·m (27 lb ft).


    Object Number: 163722  Size: SH
  153. Install the access hole plug.

  154. Object Number: 163714  Size: SH
  155. Install new O-ring seals on the vehicle speed sensors.
  156. Lubricate the vehicle speed sensor O-ring seals with transfer case fluid.
  157. Install the rear vehicle speed sensors.
  158. Tighten
    Tighten the speed senor to 15 N·m (11 lb ft).


    Object Number: 662047  Size: SH
  159. Install the front vehicle speed sensor.
  160. Tighten
    Tighten the speed senor to 15 N·m (11 lb ft).


    Object Number: 1869823  Size: SH
  161. Apply a thin layer of retaining compound GM P/N 12377901, Canadian P/N 10953504, or equivalent, to the NEW aluminum vent pipe.
  162. Tap the NEW aluminum vent pipe into the case; ensure the vent pipe is aligned in the direction shown.

  163. Object Number: 857328  Size: SH

    Important: A new encoder motor does not come with locating pins. Locating pins must be installed in the encoder motor for proper operation.

  164. Install the locating pins in the encoder motor.
  165. Install the actuator insulator gasket to the encoder motor.
  166. Install the encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
  167. Install the mounting bolts for the encoder motor.
  168. Tighten
    Tighten the encoder motor mounting bolts, in the sequence shown, to 20 N·m (15 lb ft).

  169. Install the case bolt for the wiring harness bracket.
  170. Tighten
    Tighten the case bolt to 37 N·m (27 lb ft).


    Object Number: 801307  Size: SH
  171. Using the J 45380 , install a new rear output shaft bushing.
  172. 103.1. Install the bushing on the finger section of the J 45380 .
    103.2. Install the finger section to the main body of the J 45380 .
    103.3. Position the bushing and tool to the case.
    103.4. Using a hammer and the J 45380 , install the bushing.

    Object Number: 687288  Size: SH
  173. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
  174. Important: When installing the rear output shaft seal, ensure that the drain hole is pointed down at an angle at which the transfer case would be installed in the vehicle.

  175. Using the J 37668-A , install the rear output shaft seal.

  176. Object Number: 678236  Size: SH
  177. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal.

  178. Object Number: 678288  Size: SH
  179. Using the J 42738 , install the input shaft seal.