GM Service Manual Online
For 1990-2009 cars only
Table 1: Transfer Case Holding Fixture Installation
Table 2: Access Hole Plugs, Fill and Drain Plug, Lever, Vent, Shift Control Switch, and Vehicle Speed Sensor Removal
Table 3: Rear Output Shaft Seal and Bushing Removal
Table 4: Transfer Case Rear Case Half Removal
Table 5: Oil Pump Suction Pipe and Shift Forks Removal
Table 6: Drive Chain and Rear Output Shaft Assembly Removal
Table 7: Shift Detent Plunger Assembly, Shift Detent Lever, Input Shaft, and Planetary Assembly Removal
Table 8: Front Output Shaft Assembly Removal

Transfer Case Holding Fixture Installation


Object Number: 1843573  Size: MF

Transfer Case Holding Fixture Installation

Callout

Component Name

1

Transfer Case Nuts

Special Tools

J 45759 Assembly Fixture

For equivalent regional tools, refer to Special Tools.

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.

Access Hole Plugs, Fill and Drain Plug, Lever, Vent, Shift Control Switch, and Vehicle Speed Sensor Removal


Object Number: 1843574  Size: MF

Access Hole Plugs, Fill and Drain Plug, Lever, Vent, Shift Control Switch, and Vehicle Speed Sensor Removal

Callout

Component Name

1

Transfer Case Access Hole Plugs (Qty: 2)

2

Transfer Case Oil Fill Plug

3

Transfer Case Oil Drain Plug

4

Transfer Case Control Lever Bolt/Screw

5

Transfer Case Lever

6

Transfer Case Shift Lever Washer

7

Transfer Case Vent

Tip
Remove ONLY if the vent pipe is damaged.

8

Transfer Case Shift Control Switch Assembly

9

Transfer Case Selector Switch - O-ring - Seal

10

Vehicle Speed Sensor Assembly

11

Vehicle Speed Sensor O-Ring Seal

Rear Output Shaft Seal and Bushing Removal


Object Number: 1843577  Size: MF

Rear Output Shaft Seal and Bushing Removal

Callout

Component Name

1

Transfer Case Rear Output Shaft Seal

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

2

Transfer Case Rear Output Shaft Bushing

Tip

    • Only remove the bushing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection.
    • The following procedure is for the light duty application, for the heavy duty and super heavy duty applications. Refer to Rear Output Shaft Bushing Replacement.
    • Follow the steps below for use of the J 45380 Remover/Installer .
        1. Install the finger section of the J 45380 Remover/Installer in front of the bushing.
        2. Install the tube and forcing tube assembly into the finger section. Ensure the forcing screw is backed out.
        3. Using a wrench on the forcing screw, remove the bushing.

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

Transfer Case Rear Case Half Removal


Object Number: 1843579  Size: MF

Transfer Case Rear Case Half Removal

Callout

Component Name

1

Transfer Case Bolts (Qty: 17)

2

Transfer Case Bracket

3

Transfer Case Rear Case Half

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

Tip

    • Use opposing pry bars at casting bosses to spread case.
    • Use snap ring pliers to release the transfer case rear output shaft outer retaining ring from the transfer case rear output shaft rear bearing assembly.

4

Transfer Case Front Output Shaft Driven Sprocket Spacer Spring

5

Transfer Case Front Output Shaft Driven Sprocket Spacer

Oil Pump Suction Pipe and Shift Forks Removal


Object Number: 1843580  Size: MF

Oil Pump Suction Pipe and Shift Forks Removal

Callout

Component Name

1

Transfer Case Oil Pump Suction Pipe

2

Transfer Case Oil Pump Suction Pipe Seal

3

Transfer Case Shift Fork Spring

4

Transfer Case Control Actuator Shaft

5

Transfer Case Two/Four Wheel Drive Shift Fork Assembly

6

Transfer Case High/Low Shift Fork

Drive Chain and Rear Output Shaft Assembly Removal


Object Number: 1843581  Size: MF

Drive Chain and Rear Output Shaft Assembly Removal

Callout

Component Name

1

Transfer Case Front Output Shaft Driven Sprocket

2

Transfer Case Rear Output Shaft Assembly

Tip
Mount the assembly into a soft-jaw vice or holding fixture for disassembly.

3

Transfer Case Front Output Shaft Drive Chain Assembly

4

Transfer Case High/Low Clutch

5

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

6

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip
Use an arbor press or suitable puller to remove the bearing from the rear output shaft.

7

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

8

Transfer Case Rear Output Shaft Speed Reluctor Wheel

9

Transfer Case Oil Pump Assembly

10

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

11

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

12

Transfer Case Front Output Shaft Drive Sprocket

13

Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly (Qty: 2)

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

14

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring

15

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring

16

Transfer Case Two/Four Wheel Drive Synchronizer Assembly

17

Transfer Case Two/Four Wheel Drive Synchronizer Sleeve

18

Transfer Case Two/Four Wheel Drive Synchronizer Insert (Qty: 3)

19

Transfer Case Two/Four Wheel Drive Synchronizer Hub

Shift Detent Plunger Assembly, Shift Detent Lever, Input Shaft, and Planetary Assembly Removal


Object Number: 1843582  Size: MF

Shift Detent Plunger Assembly, Shift Detent Lever, Input Shaft, and Planetary Assembly Removal

Callout

Component Name

1

Transfer Case Shift Detent Plunger Plug

2

Transfer Case Shift Detent Plunger Plug Seal

3

Transfer Case Shift Detent Spring

4

Transfer Case Shift Detent Plunger

5

Transfer Case Shift Detent Lever Assembly

6

Transfer Case Shift Lever Seal

7

Transfer Case Input Shaft Seal

8

Transfer Case Input Shaft Bearing Outer Retaining Ring

Warning: Do not rotate the transfer case while the retaining ring is removed. Rotating the transfer case while the retaining ring is removed, may cause the input shaft/planetary assembly to fall from the transfer case, resulting in personal injury.

9

Transfer Case Input Shaft/Planetary Assembly

10

Transfer Case High/Low Planetary Carrier Retaining Ring

11

Transfer Case High/Low Locking Plate

12

Transfer Case Planetary Carrier Sun Gear Thrust Washer

13

Transfer Case Input Shaft

14

Transfer Case Input Shaft Pilot Bearing Assembly

Tip
Only remove the bearing if faulty.

Refer to Front Output Shaft and Input Shaft Cleaning and Inspection.

15

Transfer Case Planetary Carrier Sun Gear Thrust Washer

16

Transfer Case High/Low Planetary Carrier Assembly

17

Transfer Case Input Shaft Inner Retaining Ring

18

Transfer Case Input Shaft Bearing Assembly

Front Output Shaft Assembly Removal


Object Number: 1843583  Size: MF

Front Output Shaft Assembly Removal

Callout

Component Name

1

Transfer Case Front Case Half

Tip
Place the front case half on an arbor press.

2

Transfer Case Front Output Shaft Assembly

Tip
Press the front output shaft assembly from the front case half using an arbor press or soft-face hammer.

3

Transfer Case Front Output Shaft Seal