Transfer Case Disassemble

Tools Required

• J 2619-01  Slide Hammer
• J 3289-20  Holding Fixture
• J 22912-01  Split-Plate Bearing Puller
• J 23907  Slide Hammer with Bearing Adapter
• J 26941  Bushing and Bearing Remover - 3-4 in
• J 45380  Transfer Case Rear Bushing Remover and Installer
• J 45548  Mainshaft Support Bushing/Bearing Remover
• J 45759  Assembly Fixture

1. Attach the J 45759  to the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759  .
   Fig 1: Attaching J 45759 To Transfer Case

   Courtesy of GENERAL MOTORS CORP.
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.
   Fig 2: View Of Front Transfer Case Bench Mount

   Courtesy of GENERAL MOTORS CORP.
4. Remove the drain plug (2) and the fill plug (1).
   Fig 3: Locating Fill & Drain Plugs

   Courtesy of GENERAL MOTORS CORP.
5. Drain the fluid from the transfer case.
6. Remove the access plug from the transfer case.
   Fig 4: Locating Transfer Case Access Plug

   Courtesy of GENERAL MOTORS CORP.
7. Remove the transfer case vehicle speed sensor.
   Fig 5: Removing Transfer Case Speed Sensor

   Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Transfer Case Seal Removal Notice .
Fig 6: Removing Input Shaft Seal
Courtesy of GENERAL MOTORS CORP.
8. Remove the input shaft seal.
9. Remove the rear output shaft seal.
   Fig 7: Removing Rear Output Shaft Seal

   Courtesy of GENERAL MOTORS CORP.
10. Inspect the rear output shaft bushing for scoring or wear.
11. Using the J 45380  , remove the rear output shaft bushing.
    Fig 8: Removing Rear Output Shaft Bushing

    Courtesy of GENERAL MOTORS CORP.
    • Install the finger section of the J 45380  in front of the bushing.
    • Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
    • Using a wrench on the forcing screw, remove the rear output shaft bushing.
NOTE: Refer to Transfer Case Seal Removal Notice .
IMPORTANT: The front output shaft seal is a two piece internal style seal. The inner seal race is a force fit on the front output shaft.
Fig 9: Prying Inner Race
Courtesy of GENERAL MOTORS CORP.
12. Remove the front output shaft seal by inserting a flat-tip screwdriver in the inner seal race.
13. Pry the inner seal race forward.
14. Using a small pry bar, move the inner seal race forward on the front output shaft.
15. Remove the inner seal race from the front output shaft.
    Fig 10: Removing Inner Part Of Seal

    Courtesy of GENERAL MOTORS CORP.
16. Insert a flat-tip screwdriver or a small pry bar between the outer lip of the front output shaft seal and the transfer case.
    Fig 11: Inserting Screwdriver Between Front Output Shaft Seal Outer Lip & Transfer Case

    Courtesy of GENERAL MOTORS CORP.
17. Remove the remaining part of the front output shaft seal from the transfer case.
    Fig 12: Removing Outer Part Of Seal

    Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Mark the location of the brackets.
• The magnesium transfer cases are using new style bolts that have a cup style washer. The cup washer is only available with the bolt. If the cup washer is not damaged, the bolt can be used again.
Fig 13: View Of Transfer Case Bolts/Studs With The Cup Style Washer
Courtesy of GENERAL MOTORS CORP.
18. Remove the transfer case bolts, washers, and brackets.
19. Insert a flat-blade screwdriver in the slot on the left side of the transfer case.
    Fig 14: Locating Slot On Left Side Of Transfer Case

    Courtesy of GENERAL MOTORS CORP.
20. Insert a flat-blade screwdriver in the slot on the right side if the transfer case.
    Fig 15: Locating Slot On Right Side On Transfer Case

    Courtesy of GENERAL MOTORS CORP.
21. With equal pressure, press down on the screwdrivers.
22. Insert a pair of snap ring pliers into the slot.
    Fig 16: Positioning Snap Ring Pliers In Access Opening

    Courtesy of GENERAL MOTORS CORP.
23. Using the snap ring pliers, open the outer rear output shaft bearing retaining ring.
24. Remove the rear case half from the front case half.
    Fig 17: Separating Case Halves

    Courtesy of GENERAL MOTORS CORP.
25. Remove the oil pump screen assembly.
    Fig 18: Locating Oil Pump Screen Assembly

    Courtesy of GENERAL MOTORS CORP.
26. Remove the rear output shaft assembly. Hold the planetary carrier in place to prevent removing it with the rear output shaft.
    Fig 19: View Of Rear Output Shaft Assembly

    Courtesy of GENERAL MOTORS CORP.
27. Remove the rear output shaft bearing retaining ring.
    Fig 20: Removing Rear Output Shaft Bearing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
28. Using the flat side of the J 22912-01  and a press, remove the rear output shaft bearing.
    Fig 21: Removing Rear Output Shaft Bearing With J 22912-01

    Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Move the oil pump retaining ring down and away from the tone wheel. This ensures that the J 22912-01  does not get caught on the retaining ring.
Fig 22: Pressing Out Speed Reluctor Wheel
Courtesy of GENERAL MOTORS CORP.
29. Using the J 22912-01  and a press, remove the speed reluctor wheel.
30. Discard the speed reluctor wheel after removal.
31. Remove the oil pump retaining ring.
    Fig 23: Removing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
Fig 24: Identifying Speed Reluctor Wheel Retaining Ring
Courtesy of GENERAL MOTORS CORP.
32. Remove the oil pump assembly.
33. Using a flat-blade screwdriver, unseat the annulus retaining ring.
    Fig 25: Unseating Annulus Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
34. Remove the annulus gear retaining ring.
    Fig 26: Removing Annulus Gear Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
35. Remove the rear output shaft.
    Fig 27: Removing Rear Output Shaft

    Courtesy of GENERAL MOTORS CORP.
36. Inspect the mainshaft rear bushing in the rear output shaft for being faulty. Refer to Cleaning and Inspection .
37. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear bushing.
    Fig 28: Removing Mainshaft Rear Bushing Using J 2619-01 & J 45548

    Courtesy of GENERAL MOTORS CORP.
38. Remove the planetary carrier assembly. Tap on the end of the mainshaft with a soft-face hammer while lifting off the planetary carrier. A spring style retaining ring holds the planetary carrier to the mainshaft.
    Fig 29: Removing Planetary Carrier Assembly

    Courtesy of GENERAL MOTORS CORP.
39. Remove the planetary carrier assembly thrust washer.
    Fig 30: Identifying Sun Gear Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
40. Remove the sun gear.
    Fig 31: Removing Sun Gear

    Courtesy of GENERAL MOTORS CORP.
41. Remove the carrier retaining ring.
    Fig 32: Identifying Carrier Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
42. Remove the mainshaft.
    Fig 33: Removing Mainshaft

    Courtesy of GENERAL MOTORS CORP.
43. Remove the planetary carrier sun gear bearing.
    Fig 34: Removing Planetary Carrier Sun Gear Bearing

    Courtesy of GENERAL MOTORS CORP.
44. Remove the driven sprocket retaining ring.
    Fig 35: Removing Driven Sprocket Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
45. Remove the drive chain assembly.
    Fig 36: Removing Drive Chain Assembly

    Courtesy of GENERAL MOTORS CORP.
46. Remove the viscous coupling.
    Fig 37: Removing Viscous Coupling

    Courtesy of GENERAL MOTORS CORP.
47. Using a flat-blade screwdriver, remove the input gear bearing retaining ring from the groove.
    Fig 38: Prying Input Gear Bearing Retaining Ring From Groove

    Courtesy of GENERAL MOTORS CORP.
48. Remove the input gear bearing retaining ring.
    Fig 39: Removing Input Gear Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
49. Remove the input gear assembly.
    Fig 40: View Of Input Gear Assembly

    Courtesy of GENERAL MOTORS CORP.
50. Remove the input gear bearing retaining ring.
    Fig 41: Removing Input Gear Bearing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
51. Using a press, remove the input bearing.
    Fig 42: Pressing Out Input Bearing

    Courtesy of GENERAL MOTORS CORP.
52. Remove the front output shaft bearing retaining ring.
    Fig 43: Removing Front Output Shaft Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
53. Remove the front output shaft assembly.
    Fig 44: Removing Front Output Shaft Assembly

    Courtesy of GENERAL MOTORS CORP.
54. Remove the front output shaft bearing retainer ring.
    Fig 45: Removing Front Output Shaft Bearing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
55. Remove the front output shaft bearing.
    Fig 46: Removing Front Output Shaft Bearing

    Courtesy of GENERAL MOTORS CORP.
56. Inspect the front output shaft rear bearing. Refer to Cleaning and Inspection .
57. Using the J 23907  (2) and the J 26941  (1), remove the front output shaft bearing from the rear case.
    Fig 47: Removing Front Output Shaft Rear Bearing With J 23907 & J 26941

    Courtesy of GENERAL MOTORS CORP.