GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J-2619-A Slide Hammer w/Adapter
    • J 3289-20 Holding Fixture
    • J 8614-01 Flange and Pulley Holding Tool
    • J 29369-2 Bushing and Bearing Remover
    • J 44737 Shift Rail Bearing Remover
    • J 44738 Bearing Remover
    • J 45358 Case Spreader
    • J 45759 Assembly Fixture

    Object Number: 1403879  Size: SH

    Important: Some manufacturing design changes that take place for this model year, include narrower retaining ring grooves in the drive sprocket hub, and the front output shaft. The 3 corresponding retaining rings measure 1.93-2.03 mm (0.075-0.079 in) wide.

  1. Remove the drain plug (2) and the fill plug (1).
  2. Drain the fluid from the transfer case.

  3. Object Number: 1403883  Size: SH
  4. Attach the J 45759 to the transfer case using 4 suitable bolts. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 .

  5. Object Number: 1403886  Size: SH
  6. Mount the J 3289-20  (1) to a sturdy workbench.
  7. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin.

  8. Object Number: 1403889  Size: SH
  9. Remove the actuator encoder motor mounting bolts.
  10. Remove the actuator encoder motor assembly and bracket.
  11. Remove the actuator insulator gasket.

  12. Object Number: 1403901  Size: SH
  13. Remove the front output flange and input flange nuts.

  14. Object Number: 1403903  Size: SH
  15. Using the J 8614-01 , remove the input flange and front output flange.
  16. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 1403905  Size: SH
  17. Remove the input seal.
  18. Remove the front output seal.

  19. Object Number: 1403907  Size: SH
  20. Remove the input gear bearing inner retaining ring.
  21. Remove the front output shaft bearing inner retaining ring.

  22. Object Number: 1403911  Size: SH
  23. Rotate the transfer case 180 degrees.
  24. Remove the rear output flange nut.

  25. Object Number: 1403917  Size: SH
  26. Using the J 8614-01 , remove the rear output flange.
  27. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 1403920  Size: SH
  28. Remove the rear output seal.

  29. Object Number: 1403924  Size: SH
  30. Remove the retainer assembly bolts.
  31. Notice: Refer to Machined Surface Damage Notice in the Preface section.

  32. Use the J 45358 to remove the retainer assembly.
  33. Inspect the rear needle bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  34. Remove the rear needle bearing from the retainer assembly, if faulty.

  35. Object Number: 1486649  Size: SH

    Important: Do not grasp the upper connection hose (1).

  36. Using a pair of needle nose pliers, pull the upper connection tube (2) from the oil pump assembly (3).

  37. Object Number: 1403927  Size: SH
  38. Remove the oil pump assembly.

  39. Object Number: 163888  Size: SH
  40. Remove the O-ring seal from the oil pump assembly.

  41. Object Number: 1403930  Size: SH
  42. Remove the rear output bearing inner retaining ring.

  43. Object Number: 1403933  Size: SH
  44. Mark the location of the 3 longer bolts for correct assembly.
  45. These bolts are for assembly plant use.

  46. Remove the transfer case retaining bolts.
  47. Notice: Refer to Machined Surface Damage Notice in the Preface section.


    Object Number: 1403936  Size: SH
  48. Evenly pry the rear case half from the front case half at the locations shown.
  49. It may be necessary to insert a block between the ears to pry against.


    Object Number: 1403937  Size: SH
  50. Remove the rear case half from the front case half.

  51. Object Number: 1403939  Size: SH
  52. Remove the oil pump suction pipe and screen from the rear case half.
  53. Disconnect the connector between the oil pump suction pipe to the oil pump screen.

  54. Object Number: 1403941  Size: SH
  55. Inspect the rear output bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  56. Remove the rear output bearing outer retaining ring, if the rear output bearing is faulty.

  57. Object Number: 1403942  Size: SH
  58. Remove the rear output bearing from the rear case half, if faulty.

  59. Object Number: 1403945  Size: SH
  60. Inspect the front output needle bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  61. Using the J-2619-A  (1) and J 29369-2  (2), remove the front output needle bearing from the rear case half, if faulty.

  62. Object Number: 1403947  Size: SH
  63. Remove the shift fork shaft spring.

  64. Object Number: 1403948  Size: SH
  65. Remove the drive sprocket retaining ring (1).
  66. Remove the driven sprocket retaining ring (2).

  67. Object Number: 1403950  Size: SH

    Important: If the drive chain and sprockets are to be used again, mark the position of the drive sprockets with the darkened link on the drive chain, in order to ensure that any wear patterns will be matched for proper installation.

  68. Remove the drive chain and the sprockets from the mainshaft and the front output shaft.

  69. Object Number: 1403952  Size: SH
  70. Remove the magnet.

  71. Object Number: 1403958  Size: SH
  72. Remove the 2/4 wheel drive synchronizer gear.

  73. Object Number: 1403956  Size: SH
  74. Remove the synchronizer sleeve and the shift fork as an assembly.

  75. Object Number: 1403960  Size: SH
  76. Remove the mainshaft assembly.

  77. Object Number: 1456798  Size: SH
  78. Remove the synchronizer hub retaining ring (4) from the mainshaft (1).
  79. Remove the synchronizer hub (3).
  80. Remove the drive sprocket hub (2).

  81. Object Number: 1403962  Size: SH
  82. Remove the high/low range sleeve and the shift fork.

  83. Object Number: 1403966  Size: SH
  84. Remove the range sleeve from the shift fork.

  85. Object Number: 1403969  Size: SH
  86. Remove the shift detent assembly.

  87. Object Number: 1403968  Size: SH
  88. Remove the sector assembly.

  89. Object Number: 1403971  Size: SH
  90. Using a soft-face hammer, remove the high/low planetary assembly.

  91. Object Number: 1403973  Size: SH
  92. Remove the planetary carrier lock plate retaining ring (1).
  93. Remove the planetary carrier lock plate (2).
  94. Remove the input gear front thrust washer (3).
  95. Remove the input gear (4).
  96. Remove the input gear rear thrust washer (5).

  97. Object Number: 1403974  Size: SH
  98. Inspect the needle bearing in the input gear for being faulty. Refer to Transfer Case Cleaning and Inspection .

  99. Object Number: 1486655  Size: SH
  100. Using the J-2619-A  (1) and J 44738  (2), remove the needle bearing from the input gear, if faulty.

  101. Object Number: 1403976  Size: SH
  102. Using a soft-face hammer, remove the front output shaft from the front case half.

  103. Object Number: 1403978  Size: SH
  104. Inspect the front output shaft bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  105. Remove the front output shaft bearing outer retaining ring, if the front output shaft bearing is faulty.

  106. Object Number: 1403980  Size: SH
  107. Remove the front output shaft bearing from the front case half, if faulty.

  108. Object Number: 1403981  Size: SH
  109. Inspect the input gear bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  110. Remove the input gear bearing outer retaining ring, if the input gear bearing is faulty.

  111. Object Number: 1403982  Size: SH
  112. Remove the input gear bearing from the front case half, if faulty.

  113. Object Number: 1486658  Size: SH
  114. Inspect the sector bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  115. Using the J-2619-A  (1) and the J 44737  (2), remove the sector bearing from the front case half if faulty.

  116. Object Number: 1403891  Size: SH
  117. Remove the vent tube, ONLY if the vent tube elbow is damaged.