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Transfer Case Assemble

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Tools Required

    Fig 1: View Of Mounting Studs
    GM165657Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Because of manufacturing design changes, the transfer case was manufactured with either 1st design high/low range shifting components or 2nd design high/low range shifting components. When assembling the transfer case, use the components that are intended for that design level. Do not interchange 1st design components with 2nd design components.
  1. If removed, install the transfer case mounting studs to the height of 29.5 mm-30.5 mm (1.16-1.20 in).
    2. Fig 2: View Of Front Transfer Case Bench Mount
    GM819573Courtesy of GENERAL MOTORS CORP.
  2. Attach the J 45759  to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759  .
  3. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin.
    4. Fig 3: Identifying Input Bearing
    GM712123Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use only new retaining rings.
  4. Install the input bearing. The cage side of the bearing faces to the case front.
    5. Fig 4: Locating Input Bearing Retaining Ring
    GM712116Courtesy of GENERAL MOTORS CORP.
  5. Install the input bearing retaining ring.
    6. Fig 5: View Of Output Shaft Front Bearing & Retaining Ring
    GM801287Courtesy of GENERAL MOTORS CORP.
  6. Install the front output shaft front bearing. The cage side of the bearing faces to the front of the case.
  7. Install the front output shaft front bearing retaining ring.
    8. Fig 6: Installing Front Output Shaft Rear Bearing
    GM801306Courtesy of GENERAL MOTORS CORP.
  8. Using the J 8092  (1) and the J 36370  (2), install the front output shaft rear bearing.
    • The lettering on the bearing faces toward the tool.
    • Use the double shoulder side of the J 36370  to install the bearing recessed in the bore.
    9. Fig 7: Using J 8092 & J 45239 To Install Control Actuator Lever Shaft Bearing
    GM857325Courtesy of GENERAL MOTORS CORP.
  9. Using the J 45239  (2) and J 8092  (1), install the control actuator lever shaft bearing. The seal on the bearing faces outward.
    10. Fig 8: Identifying Control Actuator Lever Shaft
    GM857316Courtesy of GENERAL MOTORS CORP.
  10. Using transfer case fluid, lubricate the control actuator lever shaft bearing.
  11. Install the control actuator lever shaft.
    12. Fig 9: Locating Control Actuator Lever Shaft Retaining Ring
    GM857315Courtesy of GENERAL MOTORS CORP.
  12. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.
    13. Fig 10: Installing Cup Plug
    GM804160Courtesy of GENERAL MOTORS CORP.
  13. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver.

    The installed depth of the cup plug is 26.75 mm (1.05 in) from the end of the shaft.

    14. Fig 11: Installing Tone Wheel On Front Output Shaft Using J 22873
    GM801292Courtesy of GENERAL MOTORS CORP.
  14. Using the J 22873  and a hydraulic press, install a NEW tone wheel on the front output shaft.
    15. Fig 12: Tapping Front Output Shaft Into Bearing
    GM165272Courtesy of GENERAL MOTORS CORP.
  15. Install the front output shaft assembly. Use a soft-face hammer to tap the front output shaft into the bearing.
    16. Fig 13: Installing Front Output Shaft Retaining Ring
    GM717108Courtesy of GENERAL MOTORS CORP.
  16. Install the front output shaft retaining ring.
    17. Fig 14: View Of Input Shaft Thrust Washer
    GM857314Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Depending on the version of the transfer case, it may have either a 3 pinion gear or 6 pinion gear planetary carrier assembly. The 3 pinion gear planetary carrier is used with transmission RPO M30 and the input gear splines are 27 teeth. The 6 pinion gear planetary carrier is used with transmission RPO MT1 and MN8 and the input gear splines are 32 teeth. The repair procedures are the same for both planetary carriers.
  17. Lubricate the thrust washer for the input shaft with J 36850  or equivalent.
  18. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.
    19. Fig 15: Installing Pilot Bearing In Input Shaft With J 45383
    GM801303Courtesy of GENERAL MOTORS CORP.
  19. Using the J 8092  (1) and the J 45383  (2), install the pilot bearing in the input shaft.
    20. Fig 16: View Of Input Gear
    GM165294Courtesy of GENERAL MOTORS CORP.
  20. Install the input shaft assembly.
    21. Fig 17: Identifying Input Shaft Thrust Washer
    GM857313Courtesy of GENERAL MOTORS CORP.
  21. Lubricate the input shaft thrust washer with J 36850  or equivalent.
  22. Install the input shaft thrust washer.
    23. Fig 18: Locating Input Gear Thrust Plate
    GM165308Courtesy of GENERAL MOTORS CORP.
  23. Lubricate the carrier lock plate with J 36850  or equivalent.
  24. Install the carrier lock plate.
    25. Fig 19: View Of Input Gear Retaining Ring
    GM165318Courtesy of GENERAL MOTORS CORP.
  25. Install the retaining ring for the planetary gear shaft.
    26. Fig 20: Installing Planetary Assembly
    GM165341Courtesy of GENERAL MOTORS CORP.
  26. Install the planetary gear carrier. Use a soft-face hammer to tap the input shaft into the bearing.
    27. Fig 21: Installing Input Shaft Retaining Ring
    GM164463Courtesy of GENERAL MOTORS CORP.
  27. Install the outer retaining ring for the input gear bearing.
    28. Fig 22: Shift Fork Pads
    GM1490798Courtesy of GENERAL MOTORS CORP.
  28. Install new shift fork pads.
  29. Install the range shift sleeve in the range fork.
    30. Fig 23: Checking Range Shift Fork Assembly In Sector Assembly
    GM561742Courtesy of GENERAL MOTORS CORP.
  30. Align the range shift sleeve on the planetary carrier.
  31. Align the roller on the range fork in the control actuator lever slot.
  32. Install the range shift fork.
    33. Fig 24: Locating Shift Fork Shaft
    GM165035Courtesy of GENERAL MOTORS CORP.
  33. Install the shift fork shaft.
    34. Fig 25: View Of Clutch Lever Assembly
    GM701627Courtesy of GENERAL MOTORS CORP.
  34. Install the clutch lever assembly.
    35. Fig 26: Identifying Clutch Lever Pivot Pins
    GM164482Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.
  35. Install new O-ring seals on the clutch lever pivot pins.
  36. Lubricate the O-ring seals with transfer case fluid.
    37. NOTE: Refer to Fastener Notice in Cautions and Notices.
  37. Install the clutch lever pivot pins, with the aluminum washers and O-ring seals, in the front case half.

    Tighten:  Tighten the clutch lever pivot pins to 40 N.m (30 lb ft).

    38. Fig 27: View Of Rear Output Shaft Oil Restrictor
    GM164507Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The following service procedure is to be performed only if the rear output shaft is new.
  38. Install the rear output shaft oil restrictor flush with the end of the shaft.
    39. Fig 28: Installing Clutch Housing Bearing Using J 36370
    GM857326Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to position the bearing at the proper depth, ensure that the double shoulder of the J 36370  is against the bearing.
  39. Using the J 8092  (1) and the J 36370  (2), install the clutch housing bearing.
    40. Fig 29: Installing Clutch Housing On Rear Output Shaft
    GM695496Courtesy of GENERAL MOTORS CORP.
  40. Clamp the rear output shaft in a soft-jaw vise with the front end facing up.
  41. Install the clutch housing on the rear output shaft.
    42. Fig 30: Clutch Hub
    GM1492313Courtesy of GENERAL MOTORS CORP.
  42. Install the clutch hub.
    43. Fig 31: Identifying Clutch Plates
    GM670237Courtesy of GENERAL MOTORS CORP.
  43. Install a friction clutch pressure plate.
  44. Install a steel clutch pressure plate.
  45. Continue to install the friction and the steel clutch plates, alternating until 10 friction plates and 9 steel plates are installed.
    46. Fig 32: Removing Clutch Hub Retaining Ring
    GM857310Courtesy of GENERAL MOTORS CORP.
  46. Install the clutch hub retaining ring.
    47. Fig 33: Measuring Gage Block, J 44295-4 & Spacers
    GM1361135Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A clutch plate shim package is necessary in order to have the proper shims available for setting up the clutch pack. Improper shimming can cause driveability concerns and failure of the transfer case.
  47. Securely install the base plate (4) of the J 44295  in a vise with the machined surface of the locating tabs facing up.
  48. Install the assembled rear output shaft, with the clutch housing, the inner clutch plates, and the outer clutch plates, on the base plate (4) of the J 44295  .
  49. Install the weight (1) of the J 44295  on top of the assembled clutch plates.
  50. Place the gage block (2) of the J 44295  on one of the locating tabs of the base plate (4) of the J 44295  .
  51. Place the spacer (3) under the gage block (2).
  52. Using a feeler gage, measure between the gage block (2) and the spacer (3).
  53. Measure with the gage block (2), the spacer (3), and the feeler gage on the remaining 2 locating tabs of the base plate (4).
  54. The average of the three measurements is the required shim thickness.
    55. IMPORTANT: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.
  55. Select, from the clutch plate shim package, the correct shim or shims plus or minus 0.10 mm (0.004 in). You may use a combination of two shims to obtain the correct thickness.

    The shims in the clutch plate shim package are the following thickness:

    • 0.30 mm (0.12 in)
    • 0.56 mm (0.022 in)
    • 0.81 mm (0.032 in)
    • 1.04 mm (0.041 in)
    • 1.30 mm (0.051 in)
    • 1.55 mm (0.061 in)
    • 1.80 mm (0.071 in)
    • 2.08 mm (0.081 in)
  56. Remove the weight (1) of the J 44295  .
    57. IMPORTANT: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then install the clutch plates again, it could change the measurement.
  57. Install the shim or shims.
    58. Fig 34: Ensuring Bearing Inner Bearing Race Is Properly Supported
    GM801305Courtesy of GENERAL MOTORS CORP.
  58. Using a suitable press plate and a hydraulic press, press the clutch bearing inner support in the clutch apply plate bearing. Ensure the bearing inner bearing race is supported.
    59. Fig 35: View Of Clutch Pressure Plate Bearing With Inner Support
    GM1348896Courtesy of GENERAL MOTORS CORP.
  59. Install the clutch pressure plate bearing, with the inner support, in the clutch pressure plate.
    60. Fig 36: Installing Clutch Return Spring
    GM1349235Courtesy of GENERAL MOTORS CORP.
  60. Install the clutch return spring.
  61. Install the clutch pressure plate. Align the lugs of the pressure plate with the slots in the hub.
    62. Fig 37: View Of Clutch Pressure Plate Retaining Ring
    GM1348894Courtesy of GENERAL MOTORS CORP.
  62. Install the clutch apply plate retaining ring. Push down on the apply plate to access the retaining ring groove.
    63. Fig 38: Locating Rear Output Shaft Assembly
    GM701622Courtesy of GENERAL MOTORS CORP.
  63. Align the tab on the clutch bearing inner support between the clutch lever.
  64. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
  65. Install the rear output shaft assembly.
    66. Fig 39: Identifying Drive Chains & Sprockets
    GM163905Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the marks of the drive chain and sprockets, if using the chain and sprockets again.
  66. Install the drive chain and sprockets. The blue chain links must face up, or toward the rear of the vehicle.
    67. Fig 40: View Of Drive Sprocket Retaining Ring
    GM701617Courtesy of GENERAL MOTORS CORP.
  67. Install the drive sprocket retaining ring.
    68. Fig 41: Locating Driven Sprocket Retaining Ring
    GM857307Courtesy of GENERAL MOTORS CORP.
  68. Install the driven sprocket retaining ring.
    69. Fig 42: Identifying Oil Pump Suction Pipe O-Ring
    GM163888Courtesy of GENERAL MOTORS CORP.
  69. Install a new oil pump suction pipe O-ring in the oil pump.
    70. Fig 43: Oil Pump Assembly
    GM886580Courtesy of GENERAL MOTORS CORP.
  70. Install the oil pump assembly.
  71. Install the oil pump wave spring.
    72. Fig 44: Locating Oil Pump Suction Pipe Assembly
    GM1348893Courtesy of GENERAL MOTORS CORP.
  72. Install the oil pump suction pipe assembly.
    1. Install the screen in the case.
    2. Install the suction pipe to the oil pump.
    3. Inspect for the O-ring not being damaged and in the proper position.
    73. Fig 45: Locating Magnet
    GM163856Courtesy of GENERAL MOTORS CORP.
  73. Install the transfer case magnet.
    74. Fig 46: Identifying Rear Output Shaft Speed Sensor Reluctor Wheel
    GM701592Courtesy of GENERAL MOTORS CORP.
  74. Install the rear output shaft speed reluctor wheel.
    75. Fig 47: View Of Rear Output Shaft Bearing
    GM701589Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install the rear output shaft bearing, with the groove for the retaining ring, facing up.
  75. Install the rear output shaft bearing.
    76. Fig 48: Locating Rear Output Shaft Bearing Retaining Ring
    GM701586Courtesy of GENERAL MOTORS CORP.
  76. Install the rear output shaft bearing retaining ring. Push down on the rear output shaft bearing to compress the oil pump wave spring.
    77. Fig 49: View Of Oil Pump Wear Sleeve
    GM724251Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A new oil pump wear sleeve may have a star shaped hole or a spring clip hole.
  77. If necessary, install the oil pump wear sleeve.
  78. Lightly stake the oil pump wear sleeve pin to hold the sleeve in place, if star shaped hole style.
    79. Fig 50: Identifying Locating Pins
    GM163815Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure the locating pins are installed in the front case half.
  79. Install the locating pins in the front case, if necessary.
    80. Fig 51: Applying Sealant To Front Case Sealing Surface
    GM698077Courtesy of GENERAL MOTORS CORP.
    NOTE: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.
    IMPORTANT: Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.
  80. Apply a 3 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.
    81. Fig 52: Front Case & Rear Case Half Assembly
    GM163737Courtesy of GENERAL MOTORS CORP.
  81. Align the outside retaining ring, for the rear output shaft bearing, so that it is easily accessed through the opening in the rear case half.
  82. Lower the rear case half in to place.
    83. Fig 53: Positioning Snap Ring Pliers In Access Opening
    GM649760Courtesy of GENERAL MOTORS CORP.
  83. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing.
  84. Insert a rubber coated screwdriver into one of the speed sensor holes and lift up on the speed reluctor wheel, then seat the retaining ring.
    85. Fig 54: View Of Case Half Bolts/Studs With Cup Washers
    GM1226857Courtesy of GENERAL MOTORS CORP.
    NOTE: This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. Use only the transfer case bolts/studs with the cup style aluminum washer. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.
  85. Install the case bolts with cup washers, and the brackets.

    Tighten:  Tighten the case bolts to 37 N.m (27 lb ft).

    86. Fig 55: Identifying Rubber Plug
    GM1226852Courtesy of GENERAL MOTORS CORP.
  86. Install the access hole plug.
    87. Fig 56: View Of Left Rear & Right Rear Speed Sensor
    GM1226851Courtesy of GENERAL MOTORS CORP.
  87. Install new O-ring seals on the vehicle speed sensors.
  88. Lubricate the vehicle speed sensor O-ring seals with transfer case fluid.
  89. Install the rear vehicle speed sensors.

    Tighten:  Tighten the speed sensor to 15 N.m (11 lb ft).

    90. Fig 57: View Of Vehicle Speed Sensor
    GM662047Courtesy of GENERAL MOTORS CORP.
  90. Install the front vehicle speed sensor.

    Tighten:  Tighten the speed sensor to 15 N.m (11 lb ft).

    91. Fig 58: Installing Encoder Motor Bolts
    GM857328Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A new actuator encoder motor does not come with locating pins. Locating pins must be installed in the encoder motor, for proper operation.
  91. Install the locating pins in the actuator encoder motor.
  92. Install the actuator insulator gasket to the encoder motor.
  93. Install the actuator encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
  94. Install the mounting bolts for the actuator encoder motor.

    Tighten:  Tighten the actuator encoder motor mounting bolts, in the sequence shown, to 20 N.m (15 lb ft).

  95. Install the connector in the wiring harness bracket.
    96. Fig 59: Installing Rear Output Shaft Bushing
    GM801307Courtesy of GENERAL MOTORS CORP.
  96. Using the J 45380  , install a new rear output shaft bushing.
    1. Install the bushing on the finger section of the J 45380  .
    2. Install the finger section to the main body of the J 45380  .
    3. Position the bushing and tool to the case.
    4. Using a hammer and the J 45380  , install the bushing.
    97. Fig 60: Installing Output Shaft Seal
    GM687288Courtesy of GENERAL MOTORS CORP.
  97. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
  98. Using the J 37668-A  , install the rear output shaft seal.
    99. Fig 61: J 8092 & J 43484
    GM678236Courtesy of GENERAL MOTORS CORP.
  99. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal.
    100. Fig 62: Installing Transfer Case Input Shaft Seal
    GM678288Courtesy of GENERAL MOTORS CORP.
  100. Using the J 42738  , install the input shaft seal.
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