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Home >> Chevrolet >> 2024 >> Tahoe Commercial, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - Mp 3025 (NQH) - Repair Instructions - Off Vehicle >> Repair Instructions - Off Vehicle >> Transfer Case Assemble >> Special Tools

Special Tools

Equivalent regional tools: Special Tools

GM4868748Courtesy of GENERAL MOTORS COMPANY
  1. Transfer Case Input Shaft Bearing (1) - Install
  2. Transfer Case Input Shaft Bearing Outer Retaining Ring (2) - Install NEW
  3. Transfer Case High/Low Planetary Carrier (3) - Install
  4. Transfer Case High/Low Planetary Carrier Pinion Gear Thrust Washer (4) - Install
  5. Transfer Case Input Shaft (5) - Install
  6. Transfer Case High/Low Planetary Carrier Pinion Gear Thrust Washer (6) - Install
  7. Transfer Case High/Low Locking Plate (7) - Install NEW
  8. Transfer Case Input Shaft Bearing Retaining Ring (8) - Install
  9. Transfer Case Input Shaft/Planetary Assembly (9) - Install
  10. Transfer Case Input Shaft Bearing Outer Retaining Ring (10) - Install NEW
  11. GM5539757Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Control Actuator Thrust Bearing (5) - Install

  12. Transfer Case Control Actuator Lever Bearing Assembly (4) - Install
  13. Transfer Case Scissor Mechanism Lever (3) - Install
  14. Transfer Case Scissor Lever Ball (2) - Install [3x]
  15. Transfer Case Scissor Mechanism Lever (1) - Install
  16. GM5539756Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Control Actuator Lever Bearing (4) - Install

  17. Transfer Case Control Actuator Lever Washer (3) - Install
    18. NOTE:

    Ensure the control actuator lever washer is seated into the apply plate groove.

  18. Transfer Case Four Wheel Drive Clutch Pressure Plate - Apply (2) - Install
  19. Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (1) - Install [4x]
  20. 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.

  21. 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.
  22. Install the 8 transfer case four wheel drive clutch pressure plates-friction (1) and 7 transfer case four wheel drive clutch pressure plates-steel (2) clutch plates onto the DT-48213  Clutch Pack Height Gauge (3), alternating friction and steel plates.
  23. 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.
  24. Two variations are available to measure clutch pack height, outside measurement or inside measurement. Either variation will determine the correct height.
  25. Outside Measurement
    1. 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.
    2. Repeat the process in 2 additional locations, 120 degrees from each other.
    3. The average of the 3 measurements is the clutch pack height.
  26. Inside Measurement
    1. Using an inside caliper, measure the height of the clutch pack, dimension (b), and record the results.
    2. Repeat the process in 2 additional locations, 120 degrees from each other.
    3. The average of the 3 measurements is the clutch pack height.
  27. GM6495240Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Four Wheel Drive Clutch Hub (1) - Install

  28. Transfer Case Four Wheel Drive Clutch Shim (2) - Install
    29. NOTE:

    For height checking purposes you can use the transfer case two/four wheel drive clutch retaining ring (3) saved from the disassembly step.

  29. Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (3) - Install
  30. Measure the clutch assembly height.
    1. Hold the transfer case four wheel drive clutch pressure plate (4) and transfer case four wheel drive clutch hub (1) apart. Using an inside caliper or micrometer, measure the height of the clutch assembly in the location (a) shown and record the results.
    2. Repeat the process in 2 additional locations, 120 degrees from each other.
    3. The average of the 3 measurements is the clutch assembly height.
    31. NOTE:

    A variety of shims are available to properly adjust the clearance height of the clutch assembly.

  31. Subtract the clutch pack height from the clutch assembly height. This is the clutch clearance. A 3.1 mm (0.122 in) clearance +/- 0.1 mm (0.004 in) is necessary. You may need to replace the clutch shim with a thicker shim or a thinner shim, to achieve the proper clearance in the clutch. Repeat the check to verify the clearance is to the specification.
  32. With the proper clutch clearance set, remove and discard the transfer case two/four wheel drive clutch retaining ring (3). Remove the transfer case four wheel drive clutch shim (2), and the transfer case four wheel drive clutch hub (1).
  33. GM5539755Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Alternate between the friction and steel plates until there are 8 friction plates and 7 steel plates installed.

    Transfer Case Four Wheel Drive Clutch Pressure Plate - Friction (2) - Install [8x]

  34. Transfer Case Four Wheel Drive Clutch Pressure Plate - Steel (3) - Install [7x]
  35. Transfer Case Four Wheel Drive Clutch Hub (1) - Install
  36. GM5539753Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Four Wheel Drive Clutch Shim (4) - Install

  37. Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (3) - Install NEW
  38. Transfer Case Front Output Shaft Driven Sprocket Spacer- Front (2) - Install
  39. Transfer Case Four Wheel Drive Clutch Housing (1) - Install
  40. GM5539752Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Four Wheel Drive Clutch Housing Retaining Ring (5) - Install NEW

  41. Transfer Case Front Output Shaft Drive Sprocket (4) - Install
  42. Transfer Case Front Output Shaft Driven Sprocket Spacer- Rear (3) - Install
    43. NOTE:

    Ensure the retaining ring is installed into the correct retaining ring groove on the rear output shaft.

  43. Transfer Case Front Output Shaft Drive Sprocket Retaining Ring (2) - Install
  44. Transfer Case Oil Pump (1) - Install
  45. GM5539750Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Rear Output Shaft Bearing Spacer (3) - Install

  46. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) - Install NEW
  47. Transfer Case Rear Output Shaft Rear Bearing (2) - Install
    1. Use an arbor press or suitable installer to install the bearing to the rear output shaft.
    2. Ensure the retaining ring groove in the outer race is positioned toward the rear.
  48. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) - Install NEW
  49. GM4868753Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Load all 3 components simultaneously.

    Transfer Case High/Low Shift Fork Assembly (1) - Install

  50. Transfer Case High/Low Clutch (2) - Install
  51. Transfer Case Rear Output Shaft Assembly (3) - Install
  52. GM5066695Courtesy of GENERAL MOTORS COMPANY

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

    1. Install the chain with darkened links up.
    2. Install the front output shaft assembly into the front case half while engaging the chain with the drive sprocket.
  53. Transfer Case Front Output Shaft (2) - Install
  54. Install the transfer case actuator shaft gear (3).
  55. Transfer Case Oil Pump Suction Pipe Seal (4) - Install NEW
    1. Lubricate the seal to ease installation.
    2. Install the seal to the pipe prior to inserting the pipe into the pump.
  56. Transfer Case Oil Pump Suction Pipe (5) - Install
  57. GM4867816Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Front Case Half (1) - Install

    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.

    1. Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.
    2. Apply a 2 mm (0.078 in) bead of sealant to the front case half. Adhesives, Fluids, Lubricants, and Sealers
  58. Transfer Case Rear Case Half (2) - Install
    1. Ensure the transfer case rear output shaft outer retaining ring is in place and aligned prior to mating case halves.
    2. Use snap ring pliers to open the transfer case rear output shaft outer retaining ring for the transfer case rear output shaft rear bearing assembly.
    3. Ensure snap ring is sitting properly by rotating the entire transfer case and then let gravity seat the snap ring. Listen for a definite click sound.
  59. Transfer Case Bracket (3) - - Install
    60. CAUTION:

    Refer to Fastener Caution .

    NOTE:

    Do not use power tools.

  60. Transfer Case Half Bolt (4) - Install NEW and tighten [17x] - Fastener Specifications
  61. GM4868757Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Align the notch on the seal between the rear output bearing retaining ring access holes, this will position the weep hole down.

    Using the DT-48210  Seal Installer (2) and J-8092  Driver Handle (3) install a NEW transfer case rear output shaft seal (1).

  62. GM5538484Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Apply retaining compound to the vent pipe before installation. Adhesives, Fluids, Lubricants, and Sealers

    Transfer Case Vent (1) - Install NEW

    63. NOTE:

    Apply pipe sealant to the oil fill plug before installation. Adhesives, Fluids, Lubricants, and Sealers

  63. Transfer Case Access Hole Plug (2) - Install NEW [2x]
    64. NOTE:

    Apply pipe sealant to the oil drain plug before installation. Adhesives, Fluids, Lubricants, and Sealers

  64. Transfer Case Oil Fill Plug (3) - Install - Fastener Specifications
  65. Transfer Case Oil Drain Plug (4) - Install - Fastener Specifications
    CAUTION:

    Refer to Component Fastener Tightening Caution .

  66. GM5538480Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Lightly lubricate the O-ring with clean DEXRON®VI.

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

  67. Transfer Case Two/Four Wheel Drive Actuator Position Sensor (2) - Install
  68. Transfer Case Two/Four Wheel Drive Actuator Position Sensor Bolt (3) - Install [2x] - Fastener Specifications
  69. GM5538457Courtesy of GENERAL MOTORS COMPANY

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

  70. Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw (2) - Install and tighten [4x] - Fastener Specifications
  71. GM5568879Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Ensure the bore of the front case half is free of dirt, oil, and cleaning solvent.
    • This application uses a single lip input shaft oil seal with a DRY adapter cavity and it is to be installed with the spring portion of the seal facing inward towards the internals of the transfer case.

    Install a NEW transfer case input shaft seal (1) using the DT-42738  Seal Installer (2).

  72. Install a NEW transfer case front output shaft seal (4) using the DT-50648 - A  Seal Installer (3)
  73. GM4991176Courtesy of GENERAL MOTORS COMPANY

    Use J-44636-2  Front Output Shaft Seal Installer (5) to install the transfer case front output shaft oil slinger (1).

  74. Transfer Case Front Output Shaft Boot Clamp (2) - Install NEW
  75. Transfer Case Front Output Shaft Boot (3) - Install NEW
  76. Transfer Case Front Output Shaft Boot Clamp (2) - Install NEW
  77. GM4867809Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Nut (3) - Remove [6x]

    78. NOTE:

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

  78. Remove the transfer case (4) from the GE-3289-20  Holding Fixture (1) and DT-45759  Assembly Fixture (5).
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