GM Service Manual Online
For 1990-2009 cars only
Table 1: Transfer Case Holding Fixture Installation
Table 2: Vehicle Speed Sensor, Vent Pipe, Fill and Drain Plug Removal
Table 3: Rear Output Shaft Seal and Bushing Removal
Table 4: Rear Output Shaft Rear Bearing Retainer Assembly and Oil Pump Removal
Table 5: Transfer Case Rear Case Half Removal
Table 6: Oil Pump Suction Pipe Removal
Table 7: Drive Chain and Sprockets Removal
Table 8: Front/Rear Drive Differential Carrier Assembly and Front Case Seals Removal

Transfer Case Holding Fixture Installation


Object Number: 1566222  Size: MF

Transfer Case Holding Fixture Installation

Callout

Component Name

1

Attachment Nuts

Special Tools

J 45759 Assembly Fixture

2

Transfer Case

Special Tools

J 3289-20 Holding Fixture

3

Pivot Pin

Tip

    • Always secure with the pivot pin after rotating.
    • The transfer case can be rotated 360 degrees to facilitate repair.

Vehicle Speed Sensor, Vent Pipe, Fill and Drain Plug Removal


Object Number: 1566223  Size: MF

Vehicle Speed Sensor, Vent Pipe, Fill and Drain Plug Removal

Callout

Component Name

1

Vehicle Speed Sensor

2

Vehicle Speed Sensor O-Ring

3

Transfer Case Oil Fill Plug

4

Transfer Case Oil Drain Plug

5

Transfer Case Vent Pipe

Tip
Remove ONLY if the vent pipe elbow is damaged.

Rear Output Shaft Seal and Bushing Removal


Object Number: 1566224  Size: MF

Rear Output Shaft Seal and Bushing Removal

Callout

Component Name

1

Transfer Case Rear Output Shaft Seal

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

2

Transfer Case Extension Bushing

Procedure

  1. Install the finger section of the J 45380 in front of the bushing.
  2. Install the tube and forcing screw assembly into the finger section. Ensure the forcing screw is backed out.
  3. Using a wrench on the forcing screw, remove the bushing.

Tip
Only remove the bushing if fault is found. Refer to Rear Output Shaft Rear Bearing Retainer Cleaning and Inspection .

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

Rear Output Shaft Rear Bearing Retainer Assembly and Oil Pump Removal


Object Number: 1566225  Size: MF

Rear Output Shaft Rear Bearing Retainer Assembly and Oil Pump Removal

Callout

Component Name

1

Transfer Case Bolts (Qty: 23)

2

Transfer Case Rear Output Shaft Rear Bearing Retainer Assembly

3

Transfer Case Rear Output Shaft Speed Reluctor Wheel

Tip
Discard the rear output shaft speed reluctor wheel after removal.

Special Tools

    • J 22912-B Rear Pinion and Axle Bearing Remover
    • J 44707 T Bar Push Puller
    • J 45545 Adapter 3/8 NF to 5/8 NF

4

Transfer Case Oil Pump Cover Bolts (Qty: 6)

5

Transfer Case Oil Pump Cover

6

Transfer Case Oil Pump Driven Gear

7

Transfer Case Oil Pump Drive Gear

Transfer Case Rear Case Half Removal


Object Number: 1566227  Size: MF

Transfer Case Rear Case Half Removal

Callout

Component Name

1

Transfer Case Bolts (Qty: 23)

2

Transfer Case Front Shaft Side Bracket

3

Transfer Case Mainshaft Side Bracket

4

Transfer Case Rear Case Half

Notice: Refer to Machined Surface Damage Notice in the Preface section.

Special Tools

J 45358 Case Spreader

Oil Pump Suction Pipe Removal


Object Number: 1838067  Size: MF

Oil Pump Suction Pipe Removal

Callout

Component Name

1

Transfer Case Chip Collector Magnet

2

Transfer Case Oil Pump Suction Pipe

3

Transfer Case Oil Pump Hose

4

Transfer Case Oil Pump Screen

5

Transfer Case Oil Pump Suction Pipe O-Ring Seal

6

Transfer Case Rear Output Shaft Bearing Assembly

Tip
Only remove the bearing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection .

7

Transfer Case Front Output Shaft Rear Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection .

Drive Chain and Sprockets Removal


Object Number: 1566230  Size: MF

Drive Chain and Sprockets Removal

Callout

Component Name

1

Transfer Case Rear Output Shaft

2

Transfer Case Two/Four Wheel Drive Chain

Tip

    • Remove the drive chain with the drive and driven sprockets as an assembly.
    • If the drive chain and sprockets are to be used again, mark the position of the drive sprocket with the darkened link on the drive chain, in order to ensure wear patterns will be matched for proper installation.

3

Transfer Case Two/Four Wheel Drive Driven Sprocket Outer Retaining Ring

4

Transfer Case Two/Four Wheel Drive Driven Sprocket

5

Transfer Case Front Output Shaft Bearing Retaining Yoke Ring

6

Transfer Case Shaft to Yoke Seal

7

Transfer Case Front Output Shaft

8

Transfer Case Two/Four Wheel Drive Sprocket Outer Retaining Ring

9

Transfer Case Front Output Shaft Drive Sprocket

10

Transfer Case Front Output Shaft Drive Sprocket Bearing

Tip
Only remove the bearing if faulty. Refer to Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection .

11

Transfer Case Four Wheel Drive Clutch Hub Assembly

Front/Rear Drive Differential Carrier Assembly and Front Case Seals Removal


Object Number: 1566231  Size: MF

Front/Rear Drive Differential Carrier Assembly and Front Case Seals Removal

Callout

Component Name

1

Front/Rear Drive Differential Carrier Assembly

2

Transfer Case Input Shaft Thrust Bearing Washer

3

Transfer Case Wave Washer

4

Transfer Case Input Shaft

Tip
It may be necessary to use a soft-face hammer.

5

Transfer Case Input Gear Thrust Bearing

Tip
Only remove the bearing if faulty. Refer to Front Output Shaft and Input Shaft Cleaning and Inspection .

6

Transfer Case Input Shaft Seal

7

Transfer Case Front Output Shaft Seal

8

Transfer Case Front Output Shaft Front Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Front Half Cleaning and Inspection .

9

Transfer Case Front Input Double Row Ball Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Front Half Cleaning and Inspection .