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Transfer Case Assemble

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

    Fig 1: View Of Transfer Case
    GM901211Courtesy of GENERAL MOTORS CORP.
  1. Lubricate all internal components with GM P/N 12578261 (Canadian P/N 10953455) prior to assembly.
  2. Use the EN 46342  (1) and the DT 46429  (2) in order to install the bearing (207) and seal (301). See Special Tools .
    3. Fig 2: Removing/Installing Output Shaft, Collapsible Spacer, Washer, Seal, & Bearing
    GM901152Courtesy of GENERAL MOTORS CORP.
  3. Install the output shaft (201) with bearing, NEW collapsible spacer (204) and washers (215). Note the proper installation direction of the spacer (204).
    4. Fig 3: Removing/Installing Locknut, Washer, Sealing Washer, O-Ring & Output Yoke
    GM901148Courtesy of GENERAL MOTORS CORP.
  4. Lubricate the threads of the output shaft with GM P/N 12378261 (Canadian P/N 10953455).
  5. Install the output yoke (208), NEW O-ring (302), NEW sealing washer (303), NEW washer (209), and NEW locknut (210).
    6. Fig 4: Removing/Installing J44873 & Bolts
    GM901216Courtesy of GENERAL MOTORS CORP.
  6. Secure the case in a soft-jaw vise.
    7. NOTE: Refer to Fastener Notice .
  7. Install the J 44873  and bolts.

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

    8. IMPORTANT: Rotate the output yoke several times in both directions to seat the tapered roller bearings prior to measuring the rotating torque.
  8. Tighten the locknut to 108-294 N.m (75.6-217 lb ft) while measuring the rotating torque. Tighten the nut to achieve a rotating torque of 1.15-1.71 N.m (10.2-15.1 lb in).
    • If the rotating torque exceeds 1.71 N.m (15.1 lb in), replace the collapsible spacer and assemble again.
    • If the locknut tightening torque exceeds 294 N.m (217 lb ft), replace the collapsible spacer and assemble again.
  9. Remove the J 44873  and bolts.
    10. Fig 5: Staking Locknut Using 3.5 mm Punch
    GM901237Courtesy of GENERAL MOTORS CORP.
  10. Stake the locknut using a 3.5 mm (0.138 in) punch.
    11. Fig 6: Removing/Installing Input Gear, Bearing & 25 mm Shim
    GM901141Courtesy of GENERAL MOTORS CORP.
  11. Install the input gear (214) with shim (216) and bearing (217) into the case.
    12. Fig 7: Using EN 46342
    GM1196066Courtesy of GENERAL MOTORS CORP.
  12. Using the EN 46342  (1) and the DT 46512  (2), install the oil seal into the cover. See Special Tools . Install the seal until the flat surface of the seal measures 0.00-1.0 mm (0.00-0.04 in) flush with or slightly above the surface of the cover (a).
    13. Fig 8: Installing O-Ring, Cover, Bolts & Locating Pin
    GM1330387Courtesy of GENERAL MOTORS CORP.
  13. Install a NEW O-ring (304) to the cover.
  14. Install the cover (101) and bolts (102).

    Tighten:  Tighten the bolts to 26 N.m (20 lb ft).

  15. Install the locating pin (105).
    16. Fig 9: Removing/Installing Fill Plug, Washer, Drain Plug & Washer
    GM901181Courtesy of GENERAL MOTORS CORP.
  16. Install the fill plug (401) and NEW washer (402).
  17. Install the drain plug (403) and NEW washer (404).

    Tighten:  Tighten the drain plug to 44 N.m (33 lb ft).

    18. Fig 10: View Of Transfer Case
    GM1196061Courtesy of GENERAL MOTORS CORP.
  18. Install the ventilation valve (408), hose (407), and clamps (406).
  19. Inspect the unit for proper assembly. Refer to Transfer Case Assembly Inspection .
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