Transfer Case Disassemble

Tools Required

• J 2619-01  Slide Hammer
• J 3289-20  Holding Fixture
• J 26941  Bushing and Bearing Remover - 3-4 inch. See Special Tools .
• J 45124  Puller Bridge
• J-45124-9  Puller Legs. See Special Tools .
• J 45358  Case Spreader. See Special Tools .
• J 45380  Transfer Case Rear Bushing Remover and Installer. See Special Tools .
• J 45548  Mainshaft Support Bushing/Bearing Remover. See Special Tools .
• J 45759  Assembly Fixture. See Special Tools .

Fig 1: Mounting J 45759 To Transfer Case
Courtesy of GENERAL MOTORS CORP.
1. Attach the J 45759  to the transfer case using the adapter studs. See Special Tools . All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759  . See Special Tools .
Fig 2: View Of Front Transfer Case Bench Mount
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2. Mount the J 3289-20  (1) to a sturdy workbench.
3. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin. See Special Tools .
Fig 3: View Of Transfer Case Drain Plug
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4. Remove the drain plug and the fill plug. Ensure all of the transfer case fluid is drained out of the transfer case.
Fig 4: Inserting Screwdriver Behind Inner Race Of Seal
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NOTE: Refer to Transfer Case Seal Removal Notice .
IMPORTANT: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft.
5. Remove the front output shaft seal by inserting a flat-tip screwdriver behind the inner race of the seal.
6. Pry the inner seal race forward.
Fig 5: View Of Inner Seal Race On Front Output Shaft
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7. Using a small pry bar, move the inner seal race forward on the front output shaft.
8. Remove the inner seal race from the front output shaft.
Fig 6: Inserting Screwdriver Into Space Between Outer Race Seal Lip & Transfer Case
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9. Insert a flat-tip screwdriver or a small pry bar between the outer lip of the front output shaft seal and the transfer case.
10. Remove the remaining part of the front output shaft seal from the transfer case.
Fig 7: View Of Rear Output Shaft Seal
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NOTE: Refer to Transfer Case Seal Removal Notice .
11. Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
Fig 8: View Of Transfer Case Bolts
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12. Remove the transfer case retaining bolts and washers.

    Mark the location of the brackets.

Fig 9: Separating Case Halves Using J 45358
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NOTE: Refer to Machined Surface Damage Notice .
13. Using the J 45358  between the tabs on the case halves, shear the sealer that is holding the case halves together. See Special Tools .
14. Using pry bars at each side of the case, remove the case from the locating pins.
Fig 10: View Of Rear Case Half & Front Case Half
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15. Remove the rear case half from the front case half. The rear output shaft will come with the rear case half.
Fig 11: Aligning Sun Gear
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16. Remove the rear sun gear.
Fig 12: View Of Sun Gear Thrust Washer
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17. Remove the sun gear thrust washer.
Fig 13: Identifying Planetary Differential Assembly
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18. Remove the planetary differential assembly.
Fig 14: View Of Front Sun Gear
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19. Remove the front sun gear.
Fig 15: Locating Drive Chain & Sprockets
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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.
20. Remove the chain with the drive sprocket and driven sprocket.
Fig 16: Identifying Input Shaft
Courtesy of GENERAL MOTORS CORP.
21. Remove the input shaft.
Fig 17: View Of Front Output Shaft Assembly
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22. Remove the front output shaft assembly.
Fig 18: Tapping On Front Output Shaft Cup Plug
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23. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
Fig 19: View Of Input Seal
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24. Using a hammer and a suitable punch, remove the input seal.
Fig 20: Using Special Tools To Remove Input Shaft
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25. Using the J 26941  (3), the J 45124  (1), and the J-45124-9  (2), remove the input shaft bearing for the front input shaft from the front case. See Special Tools .
Fig 21: Using Brass Drift To Remove Front Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
26. Using a brass drift, remove the front output shaft bearing from the front case half.
Fig 22: View Of Front Case Vent
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27. If necessary, remove the vent from the front case half.
Fig 23: Identifying Rear Output Shaft Bushing
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28. Using J 45380  , remove the rear output shaft bushing. See Special Tools .
Fig 24: View Of Rear Output Shaft In Rear Case Half
Courtesy of GENERAL MOTORS CORP.
29. Remove the rear output shaft from the rear case half.
    1. Spread the rear output shaft rear bearing outer retaining ring.
    2. Using a soft-face hammer, tap on the end of the rear output shaft.
Fig 25: Identifying Rear Output Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS CORP.
30. Remove the retaining ring for the rear output shaft bearing.
Fig 26: Pressing Out Rear Output Shaft Bearing
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31. Using a hydraulic press, remove the rear output shaft bearing.
Fig 27: View Of Mainshaft Rear Support Bushing
Courtesy of GENERAL MOTORS CORP.
32. Inspect the mainshaft rear support bushing in the rear output shaft for being faulty. Refer to Transfer Case Cleaning and Inspection .
33. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear support bushing from the rear output shaft. See Special Tools .
Fig 28: Using Special Tools To Remove Rear Bearing
Courtesy of GENERAL MOTORS CORP.
34. Using the J 26941  (3), the J 45124  (1), and the J-45124-9  (2), remove the rear bearing for the front output shaft from the rear case. See Special Tools .