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Home >> Cadillac >> 2021 >> XT5 Sport >> Repair and Diagnosis >> External Pages >> Different car >> Section 898 (Transfer Case - Mp 3023/3024 (NQH) - Repair Instructions - Off Vehicle) >> Repair Instructions - Off Vehicle >> Transfer Case Assemble (with MYD) >> Assemble Procedure

Assemble Procedure

WARNING: This page is about a different car, the 2023 GMC Sierra 3500 HD and 2023 GMC Sierra 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
  1. GM6306044Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Input Shaft Bearing (2) - Install NEW

  2. Transfer Case Input Shaft Inner Retaining Ring (1) - Install NEW
  3. GM6306039Courtesy of GENERAL MOTORS COMPANY

    Assemble the transfer case high/low planetary carrier (1).

    1. Transfer Case High/Low Planetary Carrier (7) - Install
    2. Transfer Case Planetary Carrier Sun Gear Thrust Washer (6) - Install
    3. Transfer Case Input Shaft (5) - Install
    4. Transfer Case Input Shaft Washer (4) - Install
    5. Transfer Case High/Low Locking Plate (3) - Install
    6. Transfer Case Input Shaft Retaining Ring (2) - Install NEW
  4. Install the assembled transfer case high/low planetary carrier (1) into the front case half.
  5. GM6305461Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    Do not rotate the transfer case and holding fixture with the retaining ring removed. Rotating may cause the input shaft/planetary assembly to fall from the transfer case, resulting in personal injury.

    Transfer Case Input Shaft Bearing Outer Retaining Ring (1) - Install NEW

  6. GM5061098Courtesy of GENERAL MOTORS COMPANY

    The DT-48213  Clutch Pack Height Gauge (3) applies a predetermined amount of pressure to the clutch pack in order to properly measure the clutch pack height. Do not use any other method than what is outlined below.

  7. Micrometers or depth gauges may also be used in conjunction with the DT-48213  Clutch Pack Height Gauge (3) to measure the clutch pack height.
    8. NOTE:

    Two variations are available to measure clutch pack height, outside measurement or inside measurement. Either variation will determine the correct height.

  8. Complete the following steps for clutch pack height measurement - outside diameter:
    1. Install the transfer case four wheel drive clutch friction plate (1) and the transfer case four wheel drive clutch pressure plate - steel (2) into the DT-48213  Clutch Pack Height Gauge (3), alternating until 13 friction plates and 12 steel plates are installed.
    2. Tighten the DT-48213  Clutch Pack Height Gauge (3) until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
    3. Using an outside caliper, measure the total combined height of the clutch pack and the DT-48213  Clutch Pack Height Gauge (3), dimension (a). Subtract the thickness of both the upper and lower portion of the DT-48213  Clutch Pack Height Gauge (3), 14 mm (0.551 in), and record the results.
    4. Repeat the process in 2 additional locations, 120 degrees from each other.
    5. The average of the 3 measurements is the clutch pack height.
  9. Complete the following steps for clutch pack height measurement - inside diameter:
    1. Install the transfer case four wheel drive clutch pressure plate - friction (1) and the transfer case four wheel drive clutch pressure plate - steel (2) into the DT-48213  Clutch Pack Height Gauge (3), alternating until 13 friction plates and 12 steel plates are installed.
    2. Tighten the DT-48213  Clutch Pack Height Gauge (3) until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
    3. Using an inside caliper, measure the height of the clutch pack, dimension (b), and record the results.
    4. Repeat the process in 2 additional locations, 120 degrees from each other.
    5. The average of the 3 measurements is the clutch pack height.
  10. GM5845642Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Scissor Mechanism Thrust Bearing (6) - Install

  11. Transfer Case Scissor Mechanism Lever (5) - Install
  12. Transfer Case Scissor Lever Ball (4) - Install [5x]
  13. Transfer Case Scissor Mechanism Lever (3) - Install
  14. Transfer Case Scissor Mechanism Thrust Bearing (2) - Install
  15. Transfer Case Four Wheel Drive Clutch Pressure Plate (1) - Install
  16. GM5845635Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Alternate between the friction and pressure plates until there are 13 friction plates and 12 pressure plates installed.

    Transfer Case Four Wheel Drive Clutch Pressure Plate (4) - Install [12x]

  17. Transfer Case Four Wheel Drive Clutch Friction Plate (3) - Install [13x]
  18. Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (2) - Install
  19. Transfer Case Clutch Hub (1) - Install
  20. GM5061355Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • A variety of shims are available to properly adjust the clearance height of the clutch assembly.
    • An inside micrometer may also be used to measure the clutch assembly height.

    Using an inside caliper, measure the height of the clutch assembly in the location (a) shown and record the results.

  21. Repeat the process in 2 additional locations, 120 degrees from each other.
  22. The average of the 3 measurements is the clutch assembly height.
  23. A 3.1 mm (0.122 in) clearance +/- 0.1 mm (0.004 in) is necessary between the clutch pack height and the assembly height. It may be necessary to replace the clutch shim with a thicker shim or a thinner shim, to achieve the proper clearance in the clutch.
  24. Subtract the clutch pack height from the clutch assembly height. The difference should be between 3.0 mm (0.118 in) and 3.2 mm (0.126 in) clearance.
  25. GM5971965Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The transfer case four wheel drive clutch shim is available in different thicknesses to achieve the proper clutch clearance.

    Transfer Case Four Wheel Drive Clutch Shim (3) - Install

  26. Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (2) - Install
  27. Transfer Case Rear Output Shaft Bearing Spacer (1) - Install
  28. GM6308701Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Rear High/Low Clutch Gear Thrust Bearing Pin (4) - Install

  29. Transfer Case Front Output Shaft Drive Sprocket (3) - Install
  30. Transfer Case Front Output Shaft Drive Sprocket Spacer (2) - Install
  31. Transfer Case Front Output Shaft Drive Sprocket Retaining Ring (1) - Install NEW
  32. GM5905964Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Oil Pump (1) - Install

  33. GM6308689Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) - Install NEW

  34. Transfer Case Rear Output Shaft Rear Bearing (2) - Install NEW
    1. Use an arbor press or suitable installer to install the transfer case rear output shaft rear bearing (2) to the rear output shaft.
    2. Ensure the retaining ring groove in the outer race is positioned toward the rear.
  35. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) - Install NEW
  36. GM6310986Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Transfer case for transmission RPO's MGM, MGU, and MKM shown. Steps are the same for transmission RPO MYD.
    • Load all 3 components simultaneously.

    Transfer Case High/Low Clutch (3) - Install

  37. Transfer Case Two/Four Wheel Drive Actuator Shaft (2) - Install
  38. Transfer Case Rear Output Shaft Assembly (1) - Install
  39. GM5735788Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Two/Four Wheel Drive Compound Gear Bracket (2) - Install

    40. CAUTION:

    Refer to Fastener Caution .

  40. Transfer Case Two/Four Wheel Drive Compound Gear Bracket Bolt (1) - Install and tighten [3x] - Fastener Specifications
  41. GM6313491Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Front Output Shaft Drive Chain (1) - Install

    1. Install the transfer case front output shaft drive chain (1) with darkened links up.
    2. Install the front output shaft assembly (2) into the front case half while engaging the transfer case front output shaft drive chain (1) with the drive sprocket.
  42. Transfer Case Two/Four Wheel Drive Compound Gear (3) - Install
  43. Lubricate the NEW transfer case oil pump suction pipe seal (4) with clean oil and install. Adhesives, Fluids, Lubricants, and Sealers
  44. Transfer Case Oil Pump Suction Pipe (5) - Install
  45. GM5744661Courtesy of GENERAL MOTORS COMPANY

    Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.

    46. CAUTION:

    Apply the proper amount of sealant to the transfer case (front half) sealing surface when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

  46. Apply a 2 mm (0.078 in) bead of sealant to the front case half. Adhesives, Fluids, Lubricants, and Sealers
  47. GM6306270Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring (3) - Install NEW

    48. NOTE:

    Ensure the NEW transfer case rear output shaft rear bearing outer retaining ring (3) is in place and aligned prior to mating case halves.

  48. Transfer Case Rear Extension (2) - Install
    1. Use snap ring pliers to open the NEW transfer case rear output shaft rear bearing outer retaining ring (3) for the transfer case rear output shaft rear bearing assembly.
    2. Mate the case halves together.
    3. Pull the transfer case rear output shaft rearward until you hear the transfer case rear output shaft rear bearing outer retaining ring (3) click into place.
    49. NOTE:

    Do not use power tools.

  49. Transfer Case Half Bolt (1) - Install and tighten [20x] - Fastener Specifications
  50. GM4868757Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Align the notch on the NEW transfer case rear output shaft seal (1) between the rear output bearing retaining ring access holes, this will position the weep hole down.

    Using the DT-48021  Seal Installer (2) and J-8092  Driver Handle (3) install a NEW transfer case rear output shaft seal (1).

  51. GM5538484Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Apply retaining compound to the transfer case vent (1) before installation. Adhesives, Fluids, Lubricants, and Sealers

    Transfer Case Vent (1) - Install NEW

  52. Transfer Case Access Hole Plug (2) - Install NEW [2x]
    53. CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    Apply pipe sealant to the transfer case oil fill plug (3) before installation. Adhesives, Fluids, Lubricants, and Sealers

  53. Transfer Case Oil Fill Plug (3) - Install - Fastener Specifications
    54. CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    Apply pipe sealant to the transfer case oil drain plug (4) before installation. Adhesives, Fluids, Lubricants, and Sealers

  54. Transfer Case Oil Drain Plug (4) - Install - Fastener Specifications
  55. GM5538480Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Two/Four Wheel Drive Actuator Position Sensor Gasket (1) - Install NEW

  56. Transfer Case Two/Four Wheel Drive Actuator Position Sensor (2) - Install
  57. Transfer Case Two/Four Wheel Drive Actuator Sensor Bolt (3) - Install and tighten [2x] - Fastener Specifications
  58. GM5538457Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Two/Four Wheel Drive Actuator (1) - Install

  59. Transfer Case Two/Four Wheel Drive Actuator Sensor Bolt (2) - Install and tighten [4x] - Fastener Specifications
  60. GM6306288Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Ensure the bores of the front case half are free of dirt, oil, and cleaning solvent.

    Using the DT-50648-A  Case Seal Installer (2), or J-42738  Seal Installer (2), install a NEW transfer case input shaft seal (1).

  61. Use the J-8092  Driver Handle (3) and DT-50649  Seal Installer (4) to install a NEW transfer case front output shaft seal (5).
    62. NOTE:

    Ensure the transfer case front output shaft oil slinger (6) is flush with the end of the front output shaft.

  62. Use the J-8092  Driver Handle (3) and DT-50649  Seal Installer (4) to install a NEW transfer case front output shaft oil slinger (6).
  63. GM5342481Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The Transfer Case Range Actuator Learn must be performed after the transfer case is installed in the vehicle.

    Remove the DT-45759  Assembly Fixture (4) and transfer case (5) from the DT-3289-20  Holding Fixture (2).

  64. Remove the DT-45759  Assembly Fixture (4) from the transfer case (5).
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