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Transfer Case Assemble

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Tools Required

    Fig 1: View Of Mounting Studs
    GM165657Courtesy of GENERAL MOTORS CORP.
  1. If removed, install the transfer case mounting studs to the height of 29.5 mm-30.5 mm (1.16-1.20 in).
    2. Fig 2: View Of Front Transfer Case Bench Mount
    GM819573Courtesy of GENERAL MOTORS CORP.
  2. Attach the J 45759  to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759  .
  3. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin.
    4. Fig 3: Identifying Input Bearing
    GM712123Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use only new retaining rings.
  4. Install the input bearing. The cage side of the bearing faces to the case front.
    5. Fig 4: Locating Input Bearing Retaining Ring
    GM712116Courtesy of GENERAL MOTORS CORP.
  5. Install the input bearing retaining ring.
    6. Fig 5: View Of Output Shaft Front Bearing & Retaining Ring
    GM801287Courtesy of GENERAL MOTORS CORP.
  6. Install the front output shaft front bearing. The cage side of the bearing faces to the front of the case.
  7. Install the front output shaft front bearing retaining ring.
    8. Fig 6: Installing Front Output Shaft Rear Bearing
    GM801306Courtesy of GENERAL MOTORS CORP.
  8. Using the J 8092  (1) and the J 36370  (2), install the front output shaft rear bearing. See Special Tools .
    • The lettering on the bearing faces toward the tool.
    • Use the double shoulder side of the J 36370  to install the bearing recessed in the bore. See Special Tools .
    9. Fig 7: Using J 8092 & J 45239 To Install Control Actuator Lever Shaft Bearing
    GM857325Courtesy of GENERAL MOTORS CORP.
  9. Using the J 45239  (2) and J 8092  (1), install the control actuator lever shaft bearing. The seal on the bearing faces outward. See Special Tools .
    10. Fig 8: Identifying Control Actuator Lever Shaft
    GM857316Courtesy of GENERAL MOTORS CORP.
  10. Using transfer case fluid, lubricate the control actuator lever shaft bearing.
  11. Install the control actuator lever shaft.
    12. Fig 9: Locating Control Actuator Lever Shaft Retaining Ring
    GM857315Courtesy of GENERAL MOTORS CORP.
  12. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.
    13. Fig 10: View Of Cup Plug
    GM804160Courtesy of GENERAL MOTORS CORP.
  13. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver.

    The installed depth of the cup plug is 26.75 mm (1.05 in) from the end of the shaft.

    14. Fig 11: Installing The Tone Wheel On The Front Output Shaft Using J 22873
    GM801292Courtesy of GENERAL MOTORS CORP.
  14. Using the J 22873  and a hydraulic press, install a NEW tone wheel on the front output shaft. See Special Tools .
    15. Fig 12: Tapping Front Output Shaft Into Bearing
    GM165272Courtesy of GENERAL MOTORS CORP.
  15. Install the front output shaft assembly. Use a soft-face hammer to tap the front output shaft into the bearing.
    16. Fig 13: Installing Front Output Shaft Retaining Ring
    GM717108Courtesy of GENERAL MOTORS CORP.
  16. Install the front output shaft retaining ring.
    17. Fig 14: View Of Input Shaft Thrust Washer
    GM857314Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Depending on the version of the transfer case, it may have either a 3 pinion gear or 6 pinion gear planetary carrier assembly. The 3 pinion gear planetary carrier is used with transmission RPO M30 and the input gear splines are 27 teeth. The 6 pinion gear planetary carrier is used with transmission RPO MT1 and MN8 and the input gear splines are 32 teeth. The repair procedures are the same for both planetary carriers.
  17. Lubricate the thrust washer for the input shaft with J 36850  , or equivalent.
  18. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.
    19. Fig 15: Installing Pilot Bearing In The Input Shaft With J 45383
    GM801303Courtesy of GENERAL MOTORS CORP.
  19. Using the J 8092  (1) and the J 45383  (2), install the pilot bearing in the input shaft. See Special Tools .
    20. Fig 16: View Of Input Gear
    GM165294Courtesy of GENERAL MOTORS CORP.
  20. Install the input shaft assembly.
    21. Fig 17: Identifying Input Shaft Thrust Washer
    GM857313Courtesy of GENERAL MOTORS CORP.
  21. Lubricate the input shaft thrust washer with J 36850  , or equivalent.
  22. Install the input shaft thrust washer.
    23. Fig 18: Locating Input Gear Thrust Plate
    GM165308Courtesy of GENERAL MOTORS CORP.
  23. Lubricate the carrier lock plate with J 36850  , or equivalent.
  24. Install the carrier lock plate.
    25. Fig 19: View Of Input Gear Retaining Ring
    GM165318Courtesy of GENERAL MOTORS CORP.
  25. Install the retaining ring for the planetary gear shaft.
    26. Fig 20: View Of Planetary Assembly
    GM165341Courtesy of GENERAL MOTORS CORP.
  26. Install the planetary gear carrier. Use a soft-face hammer to tap the input shaft into the bearing.
    27. Fig 21: View Of Outer Retaining Ring For The Input Gear Bearing
    GM164463Courtesy of GENERAL MOTORS CORP.
  27. Install the outer retaining ring for the input gear bearing.
    28. Fig 22: View Of Range Shift Sleeve & Range Shift Fork
    GM1490798Courtesy of GENERAL MOTORS CORP.
  28. Install new shift fork pads.
  29. Install the range shift sleeve in the range fork.
    30. Fig 23: Checking Range Shift Fork Assembly In Sector Assembly
    GM561742Courtesy of GENERAL MOTORS CORP.
  30. Align the range shift sleeve on the planetary carrier.
  31. Align the roller on the range fork in the control actuator lever slot.
  32. Install the range shift fork.
    33. Fig 24: Locating Shift Fork Shaft
    GM165035Courtesy of GENERAL MOTORS CORP.
  33. Install the shift fork shaft.
    34. Fig 25: View Of Clutch Lever Assembly
    GM701627Courtesy of GENERAL MOTORS CORP.
  34. Install the clutch lever assembly.
    35. Fig 26: Identifying Clutch Lever Pivot Pins
    GM164482Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.
  35. Install new O-ring seals on the clutch lever pivot pins.
  36. Lubricate the O-ring seals with transfer case fluid.
  37. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the clutch lever pivot pin threads.
    38. NOTE: Refer to Fastener Notice .
  38. Install the clutch lever pivot pins, with the aluminum washers and O-ring seals, in the front case half.

    Tighten:  Tighten the clutch lever pivot pins to 61 N.m (45 lb ft).

    39. Fig 27: View Of Rear Output Shaft Oil Restrictor
    GM164507Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The following service procedure is to be performed only if the rear output shaft is new.
  39. Install the rear output shaft oil restrictor flush with the end of the shaft.
    40. Fig 28: Installing The Clutch Housing Bearing Using J 36370
    GM857326Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to position the bearing at the proper depth, ensure that the double shoulder of the J 36370  is against the bearing. See Special Tools .
  40. Using the J 8092  (1) and the J 36370  (2), install the clutch housing bearing. See Special Tools .
    41. Fig 29: Identifying 2nd Design Rear Output Shaft By Additional Groove (2)
    GM1752657Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The press fit rear output shaft can be identified by an additional groove (2) cut into the shaft between the clutch hub retaining ring groove (1) and the clutch apply plate retaining ring groove (3).
  41. Install the clutch housing on the rear output shaft.
    42. Fig 30: Identifying Press Fit Clutch Hub
    GM1752661Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The press fit clutch hub can be identified by the letter P (2) raised and cast at the rear, 180 degrees from the locator hole (1).
  42. Place the clutch hub over the rear output shaft, aligning the clutch hub splines with the mating splines of the shaft.
    43. Fig 31: Installing Drive Sprocket
    GM1752664Courtesy of GENERAL MOTORS CORP.
  43. Place the drive sprocket removed during disassembly over the rear output shaft against the outer portion of the clutch hub. The drive sprocket will be used as a spacer to press against, in order to fully seat the clutch hub.
    44. Fig 32: Pressing Assembly Together
    GM1752667Courtesy of GENERAL MOTORS CORP.
  44. Place the rear output shaft assembly into a hydraulic press with the input end facing down and the drive sprocket (2) supporting the assembly against the hydraulic press blocks (3).
    45. IMPORTANT: A maximum of 2 500 kg (5,500 lbs) may be necessary to fully seat the rear output shaft into the clutch hub.
  45. Press the assembly together until the rear output shaft (1) has fully seated into the clutch hub (4).
  46. Remove the assembly from the hydraulic press.
  47. Clamp the rear output shaft (1) in a soft-jaw vise with the input end facing up.
    48. Fig 33: Removing Clutch Hub Retaining Ring
    GM857310Courtesy of GENERAL MOTORS CORP.
  48. Install the oil restrictor plate.
    49. IMPORTANT: If the clutch hub retaining ring cannot be installed into the groove, then the rear output shaft is not fully seated into the clutch hub and must be pressed again until seated.
  49. Install the clutch hub retaining ring into the groove.
    50. Fig 34: Identifying Clutch Plates
    GM670237Courtesy of GENERAL MOTORS CORP.
  50. Install a friction clutch pressure plate.
  51. Install a steel clutch pressure plate.
  52. Continue to install the friction and the steel clutch plates, alternating until 10 friction plates and 9 steel plates are installed.
    53. Fig 35: Measuring Gage Block, J 44295-4 & Spacers
    GM1361135Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A clutch plate shim package is necessary in order to have the proper shims available for setting up the clutch pack. Improper shimming can cause driveability concerns and failure of the transfer case.
  53. Securely install the base plate (4) of the J 44295  in a vise with the machined surface of the locating tabs facing up. See Special Tools .
  54. Install the assembled rear output shaft, with the clutch housing, the inner clutch plates, and the outer clutch plates, on the base plate (4) of the J 44295  . See Special Tools .
  55. Install the weight (1) of the J 44295  on top of the assembled clutch plates. See Special Tools .
  56. Place the gage block (2) of the J 44295  on 1 of the locating tabs of the base plate (4) of the J 44295  . See Special Tools .
  57. Place the spacer (3) of the J 44295  under the gage block (2) of the J 44295  . See Special Tools .
  58. Using a feeler gage, measure between the gage block (2) and the spacer (3).
  59. Measure with the gage block (2), the spacer (3), and the feeler gage on the remaining 2 locating tabs of the base plate (4).
    60. IMPORTANT: The specification is the average clearance remaining between the gage block (2) and the spacer (3).
  60. The average of the 3 measurements is the required shim thickness.
    61. IMPORTANT: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.
  61. Select, from the clutch plate shim package, the correct shim or shims plus or minus 0.10 mm (0.004 in). You may use a combination of 2 shims to obtain the correct thickness.

    The shims in the clutch plate shim package are the following thickness:

    • 0.30 mm (0.12 in)
    • 0.56 mm (0.022 in)
    • 0.81 mm (0.032 in)
    • 1.04 mm (0.041 in)
    • 1.30 mm (0.051 in)
    • 1.55 mm (0.061 in)
    • 1.80 mm (0.071 in)
    • 2.08 mm (0.081 in)
  62. Remove the weight (1) of the J 44295  . See Special Tools .
    63. IMPORTANT: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then install the clutch plates again, it could change the measurement.
  63. Install the shim or shims.
    64. Fig 36: Ensuring Bearing Inner Bearing Race Is Properly Supported
    GM801305Courtesy of GENERAL MOTORS CORP.
  64. Using a suitable press plate and a hydraulic press, press the clutch bearing inner support in the clutch apply plate bearing. Ensure the bearing inner bearing race is supported.
    65. Fig 37: View Of Clutch Pressure Plate Bearing With The Inner Support
    GM1348896Courtesy of GENERAL MOTORS CORP.
  65. Install the clutch pressure plate bearing, with the inner support, in the clutch pressure plate.
    66. Fig 38: Installing Clutch Return Spring
    GM1349235Courtesy of GENERAL MOTORS CORP.
  66. Install the clutch return spring.
  67. Install the clutch pressure plate. Align the lugs of the pressure plate with the slots in the hub.
    68. Fig 39: View Of Clutch Pressure Plate Retaining Ring
    GM1348894Courtesy of GENERAL MOTORS CORP.
  68. Install the clutch apply plate retaining ring. Push down on the apply plate to access the retaining ring groove.
    69. Fig 40: Locating Rear Output Shaft Assembly
    GM701622Courtesy of GENERAL MOTORS CORP.
  69. Align the tab on the clutch bearing inner support between the clutch lever.
  70. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
  71. Install the rear output shaft assembly.
    72. Fig 41: Identifying Drive Chains & Sprockets
    GM163905Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the marks of the drive chain and sprockets, if using the chain and sprockets again.
  72. Install the drive chain and sprockets. The blue chain links must face up, or toward the rear of the vehicle.
    73. Fig 42: View Of Drive Sprocket Retaining Ring
    GM701617Courtesy of GENERAL MOTORS CORP.
  73. Install the drive sprocket retaining ring.
    74. Fig 43: Locating Driven Sprocket Retaining Ring
    GM857307Courtesy of GENERAL MOTORS CORP.
  74. Install the driven sprocket retaining ring.
    75. Fig 44: Identifying Oil Pump Suction Pipe O-Ring
    GM163888Courtesy of GENERAL MOTORS CORP.
  75. Install a new oil pump suction pipe O-ring in the oil pump.
    76. Fig 45: Oil Pump Assembly
    GM886580Courtesy of GENERAL MOTORS CORP.
  76. Install the oil pump assembly.
  77. Install the oil pump wave spring.
    78. Fig 46: Locating Oil Pump Suction Pipe Assembly
    GM1348893Courtesy of GENERAL MOTORS CORP.
  78. Install the oil pump suction pipe assembly.
    1. Install the screen in the case.
    2. Install the suction pipe to the oil pump.
    3. Inspect for the O-ring not being damaged and in the proper position.
    79. Fig 47: Locating Magnet
    GM163856Courtesy of GENERAL MOTORS CORP.
  79. Install the transfer case magnet.
    80. Fig 48: Identifying Rear Output Shaft Speed Sensor Reluctor Wheel
    GM701592Courtesy of GENERAL MOTORS CORP.
  80. Install the rear output shaft speed reluctor wheel.
    81. Fig 49: View Of Rear Output Shaft Bearing
    GM701589Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install the rear output shaft bearing, with the groove for the retaining ring, facing up.
  81. Install the rear output shaft bearing.
    82. Fig 50: Locating Rear Output Shaft Bearing Retaining Ring
    GM701586Courtesy of GENERAL MOTORS CORP.
  82. Install the rear output shaft bearing retaining ring. Push down on the rear output shaft bearing to compress the oil pump wave spring.
    83. Fig 51: View Of Oil Pump Wear Sleeve
    GM724251Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A new oil pump wear sleeve may have a star shaped hole or a spring clip hole.
  83. If necessary, install the oil pump wear sleeve.
  84. Lightly stake the oil pump wear sleeve pin to hold the sleeve in place, if star shaped hole style.
    85. Fig 52: Identifying Locating Pins
    GM163815Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure the locating pins are installed in the front case half.
  85. Install the locating pins in the front case, if necessary.
    86. Fig 53: Applying Sealant To Front Case Sealing Surface
    GM698077Courtesy of GENERAL MOTORS CORP.
    NOTE: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.
    IMPORTANT: Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.
  86. Apply a 2 mm (0.078 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541), or equivalent, to the mating surfaces of the front case half.
    87. Fig 54: Front Case & Rear Case Half Assembly
    GM163737Courtesy of GENERAL MOTORS CORP.
  87. Align the outside retaining ring, for the rear output shaft bearing, so that it is easily accessed through the opening in the rear case half.
  88. Lower the rear case half in to place.
    89. Fig 55: Positioning Snap Ring Pliers In Access Opening
    GM649760Courtesy of GENERAL MOTORS CORP.
  89. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing.
  90. Insert a rubber coated screwdriver into 1 of the speed sensor holes and lift up on the speed reluctor wheel, then seat the retaining ring.
    91. Fig 56: View Of Case Half Bolts/Studs With Cup Washers
    GM1226857Courtesy of GENERAL MOTORS CORP.
    NOTE: This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. Use only the transfer case bolts/studs with the cup style aluminum washer. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.
  91. Install the case bolts with cup washers, and the brackets.

    Tighten:  Tighten the case bolts to 37 N.m (27 lb ft).

    92. Fig 57: Identifying Rubber Plug
    GM1226852Courtesy of GENERAL MOTORS CORP.
  92. Install the access hole plug.
    93. Fig 58: View Of Left Rear & Right Rear Speed Sensor
    GM1226851Courtesy of GENERAL MOTORS CORP.
  93. Install new O-ring seals on the vehicle speed sensors.
  94. Lubricate the vehicle speed sensor O-ring seals with transfer case fluid.
  95. Install the rear vehicle speed sensors.

    Tighten:  Tighten the speed sensor to 15 N.m (11 lb ft).

    96. Fig 59: View Of Vehicle Speed Sensor
    GM662047Courtesy of GENERAL MOTORS CORP.
  96. Install the front vehicle speed sensor.

    Tighten:  Tighten the speed sensor to 15 N.m (11 lb ft).

    97. Fig 60: View Of Encoder Motor Bolts Tightening Sequence
    GM857328Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A new actuator encoder motor does not come with locating pins. Locating pins must be installed in the encoder motor, for proper operation.
  97. Install the locating pins in the actuator encoder motor.
  98. Install the actuator insulator gasket to the encoder motor.
  99. Install the actuator encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
  100. Install the mounting bolts for the actuator encoder motor.

    Tighten:  Tighten the actuator encoder motor mounting bolts, in the sequence shown, to 20 N.m (15 lb ft).

  101. Install the connector in the wiring harness bracket.
    102. Fig 61: Installing Rear Output Shaft Bushing
    GM801307Courtesy of GENERAL MOTORS CORP.
  102. Using the J 45380  , install a new rear output shaft bushing. See Special Tools .
    1. Install the bushing on the finger section of the J 45380  . See Special Tools .
    2. Install the finger section to the main body of the J 45380  . See Special Tools .
    3. Position the bushing and tool to the case.
    4. Using a hammer and the J 45380  , install the bushing. See Special Tools .
    103. Fig 62: Installing Output Shaft Seal
    GM687288Courtesy of GENERAL MOTORS CORP.
  103. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
  104. Using the J 37668-A  , install the rear output shaft seal. See Special Tools .
    105. Fig 63: J 8092 & J 43484
    GM678236Courtesy of GENERAL MOTORS CORP.
  105. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal.
    106. Fig 64: Installing Transfer Case Input Shaft Seal
    GM678288Courtesy of GENERAL MOTORS CORP.
  106. Using the J 42738  , install the input shaft seal.
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