Transfer Case Disassemble

Special Tools

• J 2619-01  Slide Hammer
• J 3289-20  Holding Fixture
• J 26941  Bushing and Bearing Remover - 3-4 inch
• J 45124  Puller Bridge
• J-45124-9  Puller Legs
• J 45358  Case Spreader
• J 45380  Transfer Case Rear Bushing Remover and Installer
• J 45548  Mainshaft Support Bushing/Bearing Remover
• J 45759  Assembly Fixture

For equivalent regional tools, refer to Special Tools 

Fig 1: Attaching Special Tool To Transfer Case
Courtesy of GENERAL MOTORS CORP.
1. Attach the J 45759  assembly fixture 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  assembly fixture.
Fig 2: Front Transfer Case Bench Mount
Courtesy of GENERAL MOTORS CORP.
2. Mount the J 3289-20  holding fixture (1) to a sturdy workbench.
3. Install the J 45759  assembly fixture (2) into J 3289-20  holding fixture (1) and secure with pivot pin.
Fig 3: Transfer Case Drain Plug
Courtesy of GENERAL MOTORS CORP.
4. Remove the drain plug and the fill plug. Ensure all of the transfer case fluid is drained out of the transfer case.
Fig 4: Prying Inner Seal Race Forward
Courtesy of GENERAL MOTORS CORP.
CAUTION:

Refer to Transfer Case Seal Removal Caution .

NOTE:

The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft.

5. Remove the front output shaft seal by inserting a flat-tip screwdriver behind the inner race of the seal.
6. Pry the inner seal race forward.
Fig 5: Inner Seal Race And Front Output Shaft
Courtesy of GENERAL MOTORS CORP.
7. Using a small pry bar, move the inner seal race forward on the front output shaft.
8. Remove the inner seal race from the front output shaft.
Fig 6: Prying Outer Race From Transfer Case
Courtesy of GENERAL MOTORS CORP.
9. Insert a flat-tip screwdriver or a small pry bar between 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: Rear Output Shaft Seal
Courtesy of GENERAL MOTORS CORP.
CAUTION:

Refer to Transfer Case Seal Removal Caution .

11. Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
Fig 8: Transfer Case Retaining Bolts And Washers
Courtesy of GENERAL MOTORS CORP.
12. Remove the transfer case retaining bolts and washers.

    Mark the location of the brackets.

Fig 9: Separating Case Halves Using Special Tool
Courtesy of GENERAL MOTORS CORP.
CAUTION:

Refer to Transfer Case Seal Removal Caution .

13. Using the J 45358  case spreader between the tabs on the case halves, shear the sealer that is holding the case halves together.
14. Using pry bars at each side of the case, remove the case from the locating pins.
Fig 10: Rear Case Half And Front Case Half
Courtesy of GENERAL MOTORS CORP.
15. Remove the rear case half from the front case half. The rear output shaft will come with the rear case half.
Fig 11: Rear Sun Gear
Courtesy of GENERAL MOTORS CORP.
16. Remove the rear sun gear.
Fig 12: Sun Gear Thrust Washer
Courtesy of GENERAL MOTORS CORP.
17. Remove the sun gear thrust washer.
Fig 13: Planetary Differential Assembly
Courtesy of GENERAL MOTORS CORP.
18. Remove the planetary differential assembly.
Fig 14: Front Sun Gear
Courtesy of GENERAL MOTORS CORP.
19. Remove the front sun gear.
Fig 15: Drive Chain And Sprockets
Courtesy of GENERAL MOTORS CORP.
NOTE:

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.

20. Remove the chain with the drive sprocket and driven sprocket.
Fig 16: Input Shaft
Courtesy of GENERAL MOTORS CORP.
21. Remove the input shaft.
Fig 17: Front Output Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
22. Remove the front output shaft assembly.
Fig 18: Tapping On Front Output Shaft Cup Plug
Courtesy of GENERAL MOTORS CORP.
23. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
Fig 19: Input Seal
Courtesy of GENERAL MOTORS CORP.
24. Using a hammer and a suitable punch, remove the input seal.
Fig 20: Input Shaft And Special Tools
Courtesy of GENERAL MOTORS CORP.
25. Using the J 26941  bushing and bearing remover (3), the J 45124  puller bridge (1), and the J-45124-9  puller legs (2), remove the input shaft bearing for the front input shaft from the front case.
Fig 21: Front Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
26. Using a brass drift, remove the front output shaft bearing from the front case half.
Fig 22: Front Case Vent
Courtesy of GENERAL MOTORS CORP.
27. If necessary, remove the vent from the front case half.
Fig 23: Rear Output Shaft Bushing
Courtesy of GENERAL MOTORS CORP.
28. Using J 45380  bushing remover and installer, remove the rear output shaft bushing.
Fig 24: Rear Output Shaft And Rear Case Half
Courtesy of GENERAL MOTORS CORP.
29. Remove the rear output shaft from the rear case half.
    1. Spread the rear output shaft rear bearing outer retaining ring.
    2. Using a soft-face hammer, tap on the end of the rear output shaft.
Fig 25: Rear Output Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS CORP.
30. Remove the retaining ring for the rear output shaft bearing.
Fig 26: Pressing Out Rear Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
31. Using a hydraulic press, remove the rear output shaft bearing.
Fig 27: Mainshaft Rear Support Bushing
Courtesy of GENERAL MOTORS CORP.
32. Inspect the mainshaft rear support bushing in the rear output shaft for being faulty. Refer to Transfer Case Cleaning and Inspection .
33. Using the J 2619-01  slide hammer (1) and the J 45548  bushing/bearing remover (2), remove the mainshaft rear support bushing from the rear output shaft.
Fig 28: Using Special Tools To Remove Rear Bearing
Courtesy of GENERAL MOTORS CORP.
34. Using the J 26941  bushing and bearing remover (3), the J 45124  puller bridge (1), and the J-45124-9  puller legs (2), remove the rear bearing for the front output shaft from the rear case.