GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 3289-20 Holding Fixture
    • J 23907 Slide Hammer with Bearing Adapter
    • J 26941 Bushing and Bearing Remover - 3-4 inch
    • J 45380 Transfer Case Rear Bushing Remover and Installer
    • J 45759 Assembly Fixture

    Object Number: 824069  Size: SH

    Important: Because of manufacturing design changes, the transfer case was manufactured with either 1st design clutch components or 2nd design clutch components. The oil pump pick-up screen parts may also be a 1st design or 2nd design. When the different design components affect disassemble procedures, follow the procedures for that design level. The changes are for manufacture purposes only and do not enhance the performance of the transfer case.

  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: 857299  Size: SH
  6. Remove the fill plug (1) and the drain plug (2) and drain the transfer case fluid.

  7. Object Number: 662850  Size: SH
  8. Remove the actuator encoder motor mounting bolts.
  9. Remove the actuator encoder motor assembly.
  10. Remove the actuator insulator gasket.

  11. Object Number: 163610  Size: SH
  12. Remove the vent and the seal, only if damaged.

  13. Object Number: 1226851  Size: SH
  14. Remove the rear vehicle speed sensors (VSS).

  15. Object Number: 662047  Size: SH
  16. Remove the front VSS.

  17. Object Number: 1226852  Size: SH
  18. Remove the access hole plug.

  19. Object Number: 705373  Size: SH
  20. Remove the front output shaft dust seal.
  21. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 670241  Size: SH
  22. Remove the front output shaft seal.
  23. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 678215  Size: SH
  24. Remove the input shaft seal by prying it out of the front case.

  25. Object Number: 715670  Size: SH
  26. Remove the rear output shaft seal.

  27. Object Number: 801274  Size: SH
  28. Inspect the rear output shaft bushing for scoring or wear.
  29. Remove the rear output shaft bushing using the J 45380 .
  30. 17.1. Install the finger section of the J 45380 in front of the bushing.
    17.2. Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
    17.3. Using a wrench on the forcing screw, remove the rear output shaft bushing.

    Object Number: 1226857  Size: SH

    Important: The magnesium transfer cases are using new style bolts that have a cup style washer. The cup washer is only available with the bolt. If the cup washer is not damaged, the bolt can be used again.

  31. Remove the transfer case retaining bolts and washers.
  32. Mark the location of any brackets.

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


    Object Number: 695581  Size: SH
  33. Insert a flat-blade screwdriver into the slot on the left side of the transfer case.

  34. Object Number: 695583  Size: SH
  35. Insert a flat-blade screwdriver into the slot on the right side of the transfer case.
  36. With equal pressure, press down on the screwdrivers in order to separate the front case half and the rear case half.

  37. Object Number: 649760  Size: SH
  38. Insert a pair of snap ring pliers and release the outer retaining ring for the rear output shaft bearing.

  39. Object Number: 163737  Size: SH
  40. Remove the rear case half from the front case half.

  41. Object Number: 724251  Size: SH
  42. Remove the oil pump wear sleeve, only if it is worn or damaged.

  43. Object Number: 701586  Size: SH
  44. Remove the rear output shaft rear bearing retaining ring.

  45. Object Number: 701589  Size: SH
  46. Remove the rear output shaft rear bearing.

  47. Object Number: 701592  Size: SH
  48. Remove the rear output shaft speed sensor reluctor wheel.

  49. Object Number: 163856  Size: SH
  50. Remove the magnet.

  51. Object Number: 163872  Size: SH
  52. If 1st design, disconnect the oil pump suction pipe from the oil pump screen.
  53. If 1st design, remove the oil pump screen from the front case half.
  54. If 1st design, remove the oil pump suction pipe from the oil pump inlet hole.

  55. Object Number: 1348893  Size: SH
  56. If 2nd design, remove the oil pump suction pipe assembly. Do not remove the screen from the pipe.

  57. Object Number: 701595  Size: SH
  58. Remove the oil pump assembly.

  59. Object Number: 163888  Size: SH
  60. Remove the oil pump suction pipe O-ring from the oil pump.

  61. Object Number: 701617  Size: SH
  62. Remove the drive sprocket retaining ring.

  63. Object Number: 857307  Size: SH
  64. Remove the driven sprocket retaining ring.

  65. Object Number: 163905  Size: SH

    Important: If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.

  66. Remove the chain and sprockets.
  67. Remove the chain from the drive sprocket and driven sprocket.

  68. Object Number: 701622  Size: SH
  69. Remove the rear output shaft assembly.
  70. Mount the rear output shaft assembly in a soft-jaw vise with the input end up.

  71. Object Number: 1348894  Size: SH
  72. Remove the clutch assembly retaining ring. Push down on the clutch pressure plate to access the retaining ring.

  73. Object Number: 801276  Size: SH
  74. If 1st design, remove the clutch pressure plate assembly.
  75. If 1st design, remove the clutch pressure plate spring.

  76. Object Number: 1348895  Size: SH
  77. If 2nd design, remove the clutch pressure plate assembly.
  78. If 2nd design, remove the clutch pressure plate spring.

  79. Object Number: 801280  Size: SH
  80. If 1st design, remove the clutch pressure plate bearing, with the clutch bearing inner support, from the clutch pressure plate.
  81. If necessary, remove the retaining ring from the clutch pressure plate.

  82. Object Number: 1348896  Size: SH
  83. If 2nd design, remove the clutch pressure plate bearing, with the clutch bearing inner support, from the clutch pressure plate.

  84. Object Number: 801281  Size: SH
  85. Inspect the bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  86. If the bearing is faulty, using a hydraulic press and a suitable adapter, remove the clutch pressure plate bearing from the clutch bearing inner support.
  87. Discard the bearing after removal.

  88. Object Number: 857310  Size: SH
  89. Remove the clutch hub retaining ring.

  90. Object Number: 801282  Size: SH
  91. Remove the clutch housing and hub assembly from the rear output shaft.
  92. Important: Do not remove the oil restrictor plate on the 2nd design clutch hub. The oil restrictor plate is only serviced with the clutch hub.

  93. If 1st design, remove the clutch hub oil restrictor plate.

  94. Object Number: 801283  Size: SH
  95. Turn the clutch assembly over on a workbench.
  96. If 1st design, remove the clutch housing.
  97. If 1st design, remove the clutch hub.
  98. If 1st design, remove the clutch backing plate.

  99. Object Number: 1348897  Size: SH
  100. If 2nd design, remove the clutch hub.
  101. If 2nd design, remove the clutch housing.

  102. Object Number: 892510  Size: SH

    Important: Do not wash the clutch inner friction plates in cleaning solvent.

  103. Separate the clutch plates for inspection.
  104. Remove and discard the shim or shims.

  105. Object Number: 164507  Size: SH
  106. Remove the oil restrictor from the rear output shaft, if replacing the shaft.

  107. Object Number: 165429  Size: SH
  108. Inspect the bearing in the clutch housing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  109. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.

  110. Object Number: 701623  Size: SH
  111. Remove both of the clutch lever pivot pins along with the aluminum washers and O-ring seals.

  112. Object Number: 164548  Size: SH
  113. Remove the shift detent spring bolt.
  114. Remove the following components:
  115. • The shift detent plunger plug O-ring seal
    • The shift detent spring
    • The shift detent plunger

    Object Number: 701627  Size: SH
  116. Remove the clutch lever assembly.

  117. Object Number: 165035  Size: SH
  118. Remove the shift fork shaft.

  119. Object Number: 712346  Size: SH
  120. Remove the range shift fork and the range shift sleeve as an assembly.
  121. It may be necessary to pry the roller on the shift fork from the control actuator lever.


    Object Number: 801284  Size: SH
  122. Remove the range shift sleeve from the range shift fork.

  123. Object Number: 164463  Size: SH
  124. Remove the outer retaining ring for the input gear bearing.

  125. Object Number: 1349173  Size: SH
  126. Remove the high/low planetary carrier.

  127. Object Number: 804188  Size: SH
  128. Remove the front output shaft bearing retaining ring.

  129. Object Number: 804189  Size: SH
  130. Remove the front output shaft assembly.

  131. Object Number: 804190  Size: SH
  132. If damaged, remove the speed sensor reluctor wheel from the front output shaft using a hydraulic press.
  133. Do not use the speed sensor reluctor wheel again after removal.


    Object Number: 804191  Size: SH
  134. Remove the planetary gear shaft retaining ring.

  135. Object Number: 804192  Size: SH
  136. Remove the carrier lock plate.

  137. Object Number: 804193  Size: SH
  138. Remove the input shaft thrust washer.

  139. Object Number: 804194  Size: SH
  140. Remove the input gear from the planetary carrier.

  141. Object Number: 804195  Size: SH
  142. Remove the thrust washer.

  143. Object Number: 165322  Size: SH
  144. Inspect the pilot bearing in the input gear for being faulty. Refer to Transfer Case Cleaning and Inspection .
  145. Remove the pilot bearing from the input gear using a brass drift and a hammer.

  146. Object Number: 712116  Size: SH
  147. Remove the input bearing retaining ring.

  148. Object Number: 712123  Size: SH
  149. Remove the input bearing.

  150. Object Number: 801287  Size: SH
  151. Remove the front output shaft front bearing retainer ring.
  152. Remove the front output shaft front bearing.

  153. Object Number: 801288  Size: SH
  154. Inspect the front output shaft rear bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  155. If the bearing is faulty, remove the bearing using the J 23907  (2) and the J 26941  (1).

  156. Object Number: 801289  Size: SH
  157. Remove the retaining ring for the control actuator lever shaft.

  158. Object Number: 801290  Size: SH
  159. Remove the control actuator lever shaft.
  160. Inspect the control actuator lever bearing and seal for being faulty. Refer to Transfer Case Cleaning and Inspection .
  161. If the bearing is leaking or faulty, remove the bearing from the case.

  162. Object Number: 165657  Size: SH
  163. Remove the mounting studs, only if they are damaged.