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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (Transfer Case - NVG 246-NP8) >> Repair Instructions >> Transfer Case Disassemble

Transfer Case Disassemble

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Tools Required

    Fig 1: Identifying J 45759
    GM824069Courtesy of GENERAL MOTORS CORP.
  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  .
    2. Fig 2: View Of Front Transfer Case Bench Mount
    GM819573Courtesy 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.
    4. Fig 3: Locating Drain & Fill Plugs
    GM857299Courtesy of GENERAL MOTORS CORP.
  4. Remove the fill plug (1) and the drain plug (2) and drain the transfer case fluid.
    5. Fig 4: View Of Actuator Encoder Motor Mounting Bolts
    GM857301Courtesy of GENERAL MOTORS CORP.
  5. Remove the connector, for the actuator encoder motor wiring harness, from the bracket.
  6. Remove the actuator encoder motor mounting bolts.
  7. Remove the actuator encoder motor assembly.
  8. Remove the actuator insulator gasket.
    9. Fig 5: Identifying Case Vent & Seal
    GM857304Courtesy of GENERAL MOTORS CORP.
  9. Remove the vent and the seal, only if damaged.
    10. Fig 6: View Of Left Rear & Right Rear Speed Sensor
    GM1226851Courtesy of GENERAL MOTORS CORP.
  10. Remove the rear vehicle speed sensors (VSS).
    11. Fig 7: View Of Vehicle Speed Sensor
    GM662047Courtesy of GENERAL MOTORS CORP.
  11. Remove the front VSS.
    12. Fig 8: Identifying Rubber Plug
    GM1226852Courtesy of GENERAL MOTORS CORP.
  12. Remove the access hole plug.
    13. Fig 9: Removing Input Shaft Seal
    GM678215Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
  13. Remove the input shaft seal by prying it out of the front case.
    14. Fig 10: Removing Rear Output Shaft Seal
    GM715670Courtesy of GENERAL MOTORS CORP.
  14. Remove the rear output shaft seal.
    15. Fig 11: Removing Rear Output Shaft Bushing
    GM801274Courtesy of GENERAL MOTORS CORP.
  15. Inspect the rear output shaft bushing for scoring or wear.
  16. Remove the rear output shaft bushing using the J 45380  . See Special Tools .
    1. Install the finger section of the J 45380  in front of the bushing. See Special Tools .
    2. Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
    3. Using a wrench on the forcing screw, remove the rear output shaft bushing.
    17. Fig 12: View Of Case Half Bolts/Studs With Cup Washers
    GM1226857Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: 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.
  17. Remove the transfer case retaining bolts and washers.

    Mark the location of any brackets.

    18. Fig 13: Identifying Slot On Right Side Of Transfer Case
    GM695581Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.
  18. Insert a flat-blade screwdriver into the slot on the left side of the transfer case.
    19. Fig 14: Locating Slot On Right Side On Transfer Case
    GM695583Courtesy of GENERAL MOTORS CORP.
  19. Insert a flat-blade screwdriver into the slot on the right side of the transfer case.
  20. With equal pressure, press down on the screwdrivers in order to separate the front case half and the rear case half.
    21. Fig 15: Positioning Snap Ring Pliers In Access Opening
    GM649760Courtesy of GENERAL MOTORS CORP.
  21. Insert a pair of snap ring pliers and release the outer retaining ring for the rear output shaft bearing.
    22. Fig 16: Front Case & Rear Case Half Assembly
    GM163737Courtesy of GENERAL MOTORS CORP.
  22. Remove the rear case half from the front case half.
    23. Fig 17: View Of Oil Pump Wear Sleeve
    GM724251Courtesy of GENERAL MOTORS CORP.
  23. Remove the oil pump wear sleeve, only if worn or damaged.
    24. Fig 18: Locating Rear Output Shaft Bearing Retaining Ring
    GM701586Courtesy of GENERAL MOTORS CORP.
  24. Remove the rear output shaft rear bearing retaining ring.
    25. Fig 19: View Of Rear Output Shaft Bearing
    GM701589Courtesy of GENERAL MOTORS CORP.
  25. Remove the rear output shaft rear bearing.
    26. Fig 20: Identifying Rear Output Shaft Speed Sensor Reluctor Wheel
    GM701592Courtesy of GENERAL MOTORS CORP.
  26. Remove the rear output shaft speed sensor reluctor wheel.
    27. Fig 21: Locating Oil Pump Suction Pipe Assembly
    GM1348893Courtesy of GENERAL MOTORS CORP.
  27. Remove the oil pump suction pipe assembly. Do not remove the screen from the pipe.
    28. Fig 22: Locating Magnet
    GM163856Courtesy of GENERAL MOTORS CORP.
  28. Remove the magnet.
    29. Fig 23: Oil Pump Assembly
    GM886580Courtesy of GENERAL MOTORS CORP.
  29. Remove the oil pump wave spring.
  30. Remove the oil pump assembly.
    31. Fig 24: Identifying Oil Pump Suction Pipe O-Ring
    GM163888Courtesy of GENERAL MOTORS CORP.
  31. Remove the oil pump suction pipe O-ring from the oil pump.
    32. Fig 25: View Of Drive Sprocket Retaining Ring
    GM701617Courtesy of GENERAL MOTORS CORP.
  32. Remove the drive sprocket retaining ring.
    33. Fig 26: Locating Driven Sprocket Retaining Ring
    GM857307Courtesy of GENERAL MOTORS CORP.
  33. Remove the driven sprocket retaining ring.
    34. Fig 27: Identifying Drive Chains & Sprockets
    GM163905Courtesy of GENERAL MOTORS CORP.
    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.
  34. Remove the chain and sprockets.
  35. Remove the chain from the drive sprocket and driven sprocket.
    36. Fig 28: Locating Rear Output Shaft Assembly
    GM701622Courtesy of GENERAL MOTORS CORP.
  36. Remove the rear output shaft assembly.
  37. Mount the rear output shaft assembly, with the input end up, in a soft-jaw vise.
    38. Fig 29: View Of Clutch Pressure Plate Retaining Ring
    GM1348894Courtesy of GENERAL MOTORS CORP.
  38. Remove the clutch assembly retaining ring. Push down on the clutch apply plate to access the retaining ring.
    39. Fig 30: View Of Clutch Return Spring
    GM1349232Courtesy of GENERAL MOTORS CORP.
  39. Remove the clutch apply plate assembly.
  40. Remove the clutch return spring.
    41. Fig 31: View Of Clutch Pressure Plate Bearing With The Inner Support
    GM1348896Courtesy of GENERAL MOTORS CORP.
  41. Remove the clutch apply plate bearing and inner support from the clutch apply plate.
    42. Fig 32: Removing Clutch Pressure Plate Bearing From Clutch Bearing Inner Support
    GM801281Courtesy of GENERAL MOTORS CORP.
  42. Inspect the bearing for being faulty. Refer to Cleaning and Inspection .
  43. If the bearing is faulty, using a hydraulic press and a suitable adapter, remove the clutch apply plate bearing from the clutch bearing inner support.
  44. Discard the bearing after removal.
    45. Fig 33: Removing Clutch Hub Retaining Ring
    GM857310Courtesy of GENERAL MOTORS CORP.
  45. Remove the clutch hub retaining ring.
    46. Fig 34: View Of Clutch Housing & Hub Assembly Components
    GM1757840Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not press against the outer portion of the clutch housing (2).
  46. Reinstall the drive sprocket (3) to the clutch housing (2). The drive sprocket (3) will be used to press against.
  47. Place the rear output shaft assembly into a hydraulic press with the input end facing up and the drive sprocket (3) supporting the assembly against the hydraulic press blocks (4).
    48. IMPORTANT: A maximum of 3 200 kg (7,055 lbs) may be necessary to remove the rear output shaft (1) from the clutch hub.
  48. Press the rear output shaft (1) from the clutch hub.
    49. Fig 35: View Of Clutch Assembly Components, 2nd Design
    GM1348897Courtesy of GENERAL MOTORS CORP.
  49. Turn the clutch assembly over on a workbench.
  50. Remove the clutch housing.
    51. IMPORTANT: Do not remove the oil restrictor plate. The oil restrictor plate is only serviced with the clutch hub.
  51. Remove the clutch hub.
    52. Fig 36: Identifying Clutch Plates
    GM670237Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not wash the clutch inner friction plates in cleaning solvent.
  52. Separate the clutch plates for inspection.
  53. Remove and discard the shim or shims.
    54. Fig 37: View Of Rear Output Shaft Oil Restrictor
    GM164507Courtesy of GENERAL MOTORS CORP.
  54. Remove the oil restrictor from the rear output shaft, if replacing the shaft.
    55. Fig 38: Locating Bearing In The Clutch Housing
    GM165429Courtesy of GENERAL MOTORS CORP.
  55. Inspect the bearing in the clutch housing for being faulty. Refer to Cleaning and Inspection .
  56. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.
    57. Fig 39: Identifying Clutch Lever Pivot Pins O-Ring Seals
    GM701623Courtesy of GENERAL MOTORS CORP.
  57. Remove both of the clutch lever pivot pins with the aluminum washers and the O-ring seals.
    58. Fig 40: View Of Clutch Lever Assembly
    GM701627Courtesy of GENERAL MOTORS CORP.
  58. Remove the clutch lever assembly from the control actuator lever.
    59. Fig 41: Locating Shift Fork Shaft
    GM165035Courtesy of GENERAL MOTORS CORP.
  59. Remove the shift fork shaft.
    60. Fig 42: View Of Range Shift Fork & Range Shift Sleeve Assembly
    GM712346Courtesy of GENERAL MOTORS CORP.
  60. Remove the range shift fork and the range shift sleeve as an assembly.

    It may be necessary to lightly pry the roller on the shift fork from the control actuator lever.

    61. Fig 43: View Of Range Shift Sleeve & Range Shift Fork
    GM1490798Courtesy of GENERAL MOTORS CORP.
  61. Remove the range shift sleeve from the range shift fork.
    62. Fig 44: View Of Outer Retaining Ring For The Input Gear Bearing
    GM164463Courtesy of GENERAL MOTORS CORP.
  62. Remove the input gear bearing outer retaining ring.
    63. Fig 45: View Of High/Low Planetary Carrier
    GM712161Courtesy 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.
  63. Remove the high/low planetary carrier.
    64. Fig 46: View Of Input Gear Retaining Ring
    GM165318Courtesy of GENERAL MOTORS CORP.
  64. Remove the planetary gear shaft retaining ring.
    65. Fig 47: Locating Input Gear Thrust Plate
    GM165308Courtesy of GENERAL MOTORS CORP.
  65. Remove the planetary carrier lock ring.
    66. Fig 48: Identifying Input Shaft Thrust Washer
    GM857313Courtesy of GENERAL MOTORS CORP.
  66. Remove the input gear front thrust washer.
    67. Fig 49: View Of Input Gear
    GM165294Courtesy of GENERAL MOTORS CORP.
  67. Remove the input gear from the planetary carrier.
    68. Fig 50: View Of Input Shaft Thrust Washer
    GM857314Courtesy of GENERAL MOTORS CORP.
  68. Remove the input gear rear thrust washer.
    69. Fig 51: Removing Pilot Bearing From Input Gear
    GM165322Courtesy of GENERAL MOTORS CORP.
  69. Inspect the pilot bearing in the input gear for being faulty. Refer to Cleaning and Inspection .
  70. Remove the pilot bearing from the input gear using a brass drift and a hammer.
    71. Fig 52: Identifying Front Output Shaft Bearing Inner Retaining Ring
    GM895080Courtesy of GENERAL MOTORS CORP.
  71. Remove the inner retaining ring for the front output shaft bearing.
    72. Fig 53: Removing Front Output Shaft With Bearing
    GM895089Courtesy of GENERAL MOTORS CORP.
  72. Using a soft-face hammer, remove the front output shaft, with the bearing, from the front case half.
    73. Fig 54: Locating Front Output Shaft Seal
    GM895092Courtesy of GENERAL MOTORS CORP.
  73. Using a suitable punch, remove the front output shaft seal from the front case half.
    74. Fig 55: View Of Front Output Shaft Bearing Outer Retaining Ring
    GM895094Courtesy of GENERAL MOTORS CORP.
  74. Remove the outer retaining ring for the front output shaft bearing.
    75. Fig 56: Identifying Front Output Shaft Bearing
    GM895096Courtesy of GENERAL MOTORS CORP.
  75. Inspect the front output shaft bearing for being faulty. Refer to Cleaning and Inspection .
  76. Remove the bearing from the front output shaft. Do not use the bearing again after removal.
    77. Fig 57: Locating Speed Sensor Reluctor Wheel
    GM801286Courtesy of GENERAL MOTORS CORP.
  77. If damaged, remove the speed sensor reluctor wheel from the front output shaft, using a hydraulic press. Do not use the speed sensor reluctor wheel again after removal.
    78. Fig 58: Removing Cup Plug
    GM165060Courtesy of GENERAL MOTORS CORP.
  78. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
    79. Fig 59: Locating Input Bearing Retaining Ring
    GM712116Courtesy of GENERAL MOTORS CORP.
  79. Remove the input bearing retaining ring.
    80. Fig 60: Identifying Input Bearing
    GM712123Courtesy of GENERAL MOTORS CORP.
  80. Remove the input bearing.
    81. Fig 61: Removing Front Output Shaft Rear Bearing With J 23907 & J 26941
    GM801288Courtesy of GENERAL MOTORS CORP.
  81. Inspect the front output shaft rear bearing for being faulty. Refer to Cleaning and Inspection .
  82. If the bearing is faulty, remove the bearing using the J 23907  (2) and the J 26941  (1). See Special Tools .
    83. Fig 62: Locating Control Actuator Lever Shaft Retaining Ring
    GM857315Courtesy of GENERAL MOTORS CORP.
  83. Remove the control actuator lever shaft retaining ring.
    84. Fig 63: Identifying Control Actuator Lever Shaft
    GM857316Courtesy of GENERAL MOTORS CORP.
  84. Remove the control actuator lever shaft.
  85. Inspect the control actuator lever bearing and seal for being faulty. Refer to Cleaning and Inspection .
  86. If the bearing is leaking or faulty, remove the bearing from the case.
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