Transfer Case Disassemble

Tools Required

• J 3289-20  Holding Fixture
• J 22912-B  Rear Pinion and Axle Bearing Remover
• J 23907  Slide Hammer with Bearing Adapter
• J 26941  Bushing and Bearing Remover - 3-4 inch
• J 36825  Output Shaft Oil Seal Remover - 4WD Models Only. See Special Tools .
• J 45358  Case Spreader. See Special Tools .
• J 45759  Assembly Fixture. See Special Tools .
• J 45849  Bearing Remover. See Special Tools .

Fig 1: Identifying J 3289-20
Courtesy of GENERAL MOTORS CORP.
1. Mount the J 3289-20  to a sturdy workbench.
2. Attach the J 45759  on 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 J 45759 & J 3289-20
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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. Ensure all of the transfer case fluid is drained out of the transfer case.
Fig 4: Inserting Screwdriver Behind Inner Race of Front Output Shaft Seal
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NOTE: Refer to Transfer Case Seal Removal Notice .
IMPORTANT: The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.
5. Remove the front input shaft seal by inserting a flat-tipped 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 input shaft.
8. Remove the inner seal race from the front input shaft.
Fig 6: Inserting Screwdriver Into Space Between Outer Race Seal Lip & Transfer Case
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9. Insert a flat-tipped screwdriver or a small pry bar between the lip of 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 Vehicle Speed Sensor (VSS) With O-Ring Seal
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11. Remove the vehicle speed sensor (VSS) with O-ring seal.
Fig 8: Identifying Rear Output Shaft Seal
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NOTE: Refer to Transfer Case Seal Removal Notice .
12. Remove the rear output shaft seal by prying out with a flat-blade screwdriver.
Fig 9: Locating Transfer Case Retaining Bolts
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13. Remove the transfer case retaining bolts and the washers.
14. Mark the location of the brackets.
Fig 10: Identifying J 45358
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NOTE: Refer to Machined Surface Damage Notice .
15. Using the J 45358  between the tabs on the case halves, shear the sealer holding the case halves together. See Special Tools .
16. Using pry bars at each side of the case, remove the case from the locating pins.
Fig 11: View Of Rear Case Half & Front Case Half
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17. Remove the rear case half from the front case half. The rear output shaft will come out with the rear case half.
Fig 12: View Of Planetary Carrier Assembly Thrust Washer
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18. Remove the planetary carrier assembly thrust washer.
Fig 13: Identifying Planetary Carrier Assembly
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19. Remove the planetary carrier assembly.
Fig 14: Locating Sun Gear Thrust Washer
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20. Remove the sun gear thrust washer.
Fig 15: View Of Front Input Shaft
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21. Remove the front input shaft.
Fig 16: Removing Front Output Shaft Cup Plug
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22. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
Fig 17: View Of Chain With Driven Sprocket
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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.
23. Remove the chain with the driven sprocket.
Fig 18: View Of Sun Gear Assembly
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24. Remove the sun gear with the drive gear and viscous coupling. Lift up on the sun gear assembly while tapping down on the input shaft with a soft-face hammer.
Fig 19: Installing J 22912-01 On Sun Gear Assembly
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25. Using a hydraulic press and J 22912-B  , remove the bearing from the sun gear.
Fig 20: View Of Drive Gear From Sun Gear Assembly
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26. Remove the drive gear from the sun gear.
Fig 21: Identifying Viscous Coupling
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27. Remove the viscous coupling from the sun gear.
Fig 22: Locating Input Shaft
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28. Remove the input shaft from the front case.
Fig 23: Removing Input Shaft Seal Using J 23907 & J 36825
Courtesy of GENERAL MOTORS CORP.
29. Using the J 23907  (1) and the J 36825  (2), remove the input seal. See Special Tools .
    1. Poke a hole in the seal using a very sharp punch.
    2. Thread the J 36825  (2) into the hole. See Special Tools .
Fig 24: Removing Input Shaft Bushing From Front Case
Courtesy of GENERAL MOTORS CORP.
30. Remove the input shaft bushing from the front case using a hammer and brass drift.
Fig 25: Removing Front Output Shaft Bearing
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31. Using a brass drift, remove the front output shaft bearing from the front case half.
Fig 26: Transfer Case Vent
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32. If necessary, remove the vent from the front case half.
Fig 27: Spreading Rear Output Shaft Rear Bearing Outer Retaining Ring
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33. Remove the rear output shaft from the rear case half.
    1. Spread the rear output shaft rear bearing outer retaining ring (1).
    2. Using a soft-face hammer, tap on the end of the rear output shaft.
Fig 28: Locating Annulus Gear Retaining Ring
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34. Remove the annulus gear retaining ring.
Fig 29: View Of Rear Output Shaft From The Annulus Gear
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35. Remove the rear output shaft from the annulus gear.
Fig 30: Removing Rear Output Shaft Bearing With J 45849
Courtesy of GENERAL MOTORS CORP.
36. Inspect the bearing in the rear output shaft. Refer to Cleaning and Inspection .
37. If the bearing is faulty, remove the bearing using the J 45849  . See Special Tools .
    • Install the finger part of the J 45849  in the bearing. See Special Tools .
    • Thread the driver part into the fingers.
    • Remove the bearing from the fingers by squeezing the fingers together.
Fig 31: Identifying Rear Output Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS CORP.
38. Remove the retaining ring for the rear output shaft bearing and the speed reluctor wheel.
Fig 32: Pressing Out Speed Reluctor Wheel With J 22912-01
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39. Using a hydraulic press and the J 22912-B  , remove the speed reluctor wheel and the rear output shaft bearing

    Do not use the speed reluctor wheel again.

Fig 33: Removing Front Output Shaft Rear Bearing With J 26941 & J 23907
Courtesy of GENERAL MOTORS CORP.
40. Remove the rear bearing for the front output shaft from the rear case, using the J 26941  (1) and the J 23907  (2).