GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 3289-20 Holding Fixture
    • J 8092 Universal Driver Handle
    • J 22912-B Split Plate Bearing Puller
    • J 23907 Slide Hammer with Bearing Adapter
    • J 29369-1 Bushing and Bearing Remover
    • J 33790 Bearing Remover
    • J 45380 Transfer Case Rear Bushing Remover and Installer
    • J 45759 Assembly Fixture

    Object Number: 824069  Size: SH
  1. Attach the J 45759 to the transfer case using the adapter studs or bolts. 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 a pivot pin.

  5. Object Number: 153330  Size: SH

    Important: If a bearing is found to be defective, it is not recommended that the bearing be replaced separately. The bearing may only be available in a subassembly.

  6. Remove the speed sensor.

  7. Object Number: 562968  Size: SH
  8. Remove the encoder motor mounting bolts.
  9. Remove the encoder motor assembly.

  10. Object Number: 562963  Size: SH
  11. Remove the detent assembly.

  12. Object Number: 564547  Size: SH
  13. Remove the first front output shaft retaining ring.
  14. Remove the front output shaft rubber washer.
  15. Remove the front output shaft seal.
  16. Remove the second front output shaft retaining ring.

  17. Object Number: 1225128  Size: SH
  18. Inspect the rear output shaft bushing for scoring or wear.
  19. Remove the rear output shaft bushing using the J 45380 .
  20. 13.1. Install the finger section of the J 45380 in front of the bushing.
    13.2. Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
    13.3. Using a wrench on the forcing screw, remove the rear output shaft bushing.

    Object Number: 153341  Size: SH
  21. Remove the rear extension housing mounting bolts.
  22. Remove the rear extension housing.

  23. Object Number: 562510  Size: SH
  24. Remove the rear output shaft retaining ring.

  25. Object Number: 562517  Size: SH
  26. Remove the rear output shaft bearing housing mounting bolts.
  27. Remove the rear output shaft bearing housing.

  28. Object Number: 562523  Size: SH
  29. Remove the first tone wheel retaining ring.
  30. Remove the tone wheel.
  31. Remove the second tone wheel retaining ring.

  32. Object Number: 562530  Size: SH
  33. Remove the transfer case retaining bolts.
  34. Remove the rear case half from the front case half.

  35. Object Number: 562073  Size: SH
  36. Remove the oil pump pick-up assembly.
  37. Remove the oil pump assembly.

  38. Object Number: 562070  Size: SH

    Important: 

       • If the drive chain is to be used again, mark the relationship of the drive chain to the sprockets. This will ensure that the wear pattern on the drive chain and the drive sprockets will be matched during assembly.
       • The drive sprocket is part of the synchronizer assembly and can only be removed from the front of the rear output shaft.
       • The driven sprocket is part of the front output shaft and not a separate part.

  39. Remove the drive chain and the front output shaft.

  40. Object Number: 562069  Size: SH
  41. Remove the mode fork retaining spring assembly.

  42. Object Number: 562066  Size: SH

    Important: When performing the following service procedure, remove the rear output shaft and the mode fork as an assembly.

  43. Remove the rear output shaft assembly.

  44. Object Number: 562063  Size: SH
  45. Remove the mode fork from the rear output shaft.

  46. Object Number: 561742  Size: SH
  47. Remove the low range fork assembly.

  48. Object Number: 561746  Size: SH
  49. Remove the range shift sleeve.

  50. Object Number: 561417  Size: SH
  51. Remove the sector shaft retaining ring.
  52. Remove the sector shaft plastic sleeve.
  53. Remove the sector shaft O-ring.

  54. Object Number: 561422  Size: SH
  55. Remove the sector shaft.

  56. Object Number: 561610  Size: SH
  57. Remove the input shaft bearing retainer mounting bolts.

  58. Object Number: 561430  Size: SH
  59. Remove the input shaft retaining ring.

  60. Object Number: 729523  Size: SH
  61. Using the J 22912-B , remove the input shaft bearing.

  62. Object Number: 560041  Size: SH
  63. Remove the planetary gear assembly.

  64. Object Number: 560051  Size: SH

    Important: It is not necessary to break down the synchronizer assembly into individual pieces. If any part of the synchronizer assembly is found to be excessively worn or damaged, replace the synchronizer as an assembly.

  65. Remove the synchronizer assembly retaining ring.
  66. Remove the synchronizer assembly.
  67. Remove the synchronizer ring.
  68. Remove the drive sprocket.

  69. Object Number: 165318  Size: SH
  70. Remove the input gear retaining ring.

  71. Object Number: 165308  Size: SH
  72. Remove the thrust plate from the planetary gear.

  73. Object Number: 165300  Size: SH
  74. Remove the thrust washer from the planetary gear.

  75. Object Number: 165294  Size: SH
  76. Remove the input gear.

  77. Object Number: 165286  Size: SH
  78. Remove the thrust washer.
  79. Remove the input seal.
  80. Remove the output shaft seal.
  81. Using the J 29369 and the J 23907 , remove the input gear pilot bearing.

  82. Object Number: 555834  Size: SH
  83. Remove the front output shaft retaining ring.
  84. Using the J 33790 and the J 8092 , remove the front output shaft front bearing from the from case.
  85. Using the J 33790 and the J 8092 , remove the output shaft rear bearing from the retainer.
  86. Using the J 33790 and the J 8092 , remove the front input shaft bearing.