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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> Transmission >> Transfer Case - BW 4484 >> Repair Instructions - Off Vehicle >> Transfer Case Disassemble >> Disassemble

Transfer Case Disassemble: Disassemble

    Fig 1: Identifying J 45759
    GM824069Courtesy of GENERAL MOTORS CORP.
  1. Using the adapter studs, attach the J 45759  to the transfer case. See Special Tools . All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759  . See Special Tools .
    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 the J 3289-20  (1) and secure with pivot pin. See Special Tools .
    4. Fig 3: View Of Transfer Case Plug
    GM819569Courtesy 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.
    5. Fig 4: Inserting Screwdriver Behind Inner Race of Front Output Shaft Seal
    GM819585Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Transfer Case Seal Removal Notice .
    IMPORTANT: The front output shaft seal is a 2-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.
    7. Fig 5: View Of Inner Seal Race On Front Output Shaft
    GM819650Courtesy 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.
    9. Fig 6: Inserting Screwdriver Into Space Between Outer Race Seal Lip & Transfer Case
    GM819658Courtesy of GENERAL MOTORS CORP.
  9. Insert a flat-tipped 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.
    11. Fig 7: View Of Transfer Case Encoder Motor & Bolts
    GM819575Courtesy of GENERAL MOTORS CORP.
  11. Remove the encoder motor bracket bolt.
  12. Remove the encoder motor mounting bolts.
  13. Remove the encoder motor assembly.
    14. Fig 8: View Of Vehicle Speed Sensor (VSS) & O-Ring Seal
    GM819577Courtesy of GENERAL MOTORS CORP.
  14. Remove the rear vehicle speed sensor (VSS) and the O-ring seal.
    15. Fig 9: Removing Rear Output Shaft Seal
    GM819580Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Transfer Case Seal Removal Notice .
  15. Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
  16. Remove the shipping seal from the rear output shaft, if equipped.
    17. Fig 10: View Of Transfer Case Bolts
    GM819583Courtesy of GENERAL MOTORS CORP.
  17. Remove the transfer case retaining bolts and washers.

    Mark the location of the brackets.

    18. Fig 11: Identifying J 45358
    GM819584Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Machined Surface Damage Notice .
  18. Using the J 45358  between the tabs on the case halves, shear the sealer that is holding the case halves together. See Special Tools .
  19. Using pry bars at each side of the case, remove the case from the locating pins.
    20. Fig 12: Rear Case Half & Front Case Half
    GM819587Courtesy of GENERAL MOTORS CORP.
  20. Remove the rear case half from the front case half. The rear output shaft will come with the rear case half.
    21. Fig 13: Identifying Shift Fork Shaft Spring
    GM819589Courtesy of GENERAL MOTORS CORP.
  21. Remove the shift fork shaft spring.
    22. Fig 14: View Of Rear Sun Gear
    GM819648Courtesy of GENERAL MOTORS CORP.
  22. Remove the rear sun gear.
    23. Fig 15: Locating Rear Output Shaft Thrust Washer
    GM819590Courtesy of GENERAL MOTORS CORP.
  23. Remove the rear output shaft thrust washer.
    24. Fig 16: View Of Planetary Differential Assembly
    GM819593Courtesy of GENERAL MOTORS CORP.
  24. Remove the planetary differential assembly.
    25. Fig 17: Identifying Front Sun Gear
    GM819595Courtesy of GENERAL MOTORS CORP.
  25. Remove the front sun gear.
    26. Fig 18: View Of Drive Chain & Sprockets
    GM819597Courtesy 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.
  26. Remove the chain with the drive sprocket and driven sprocket.
    27. Fig 19: Identifying Drive Sprocket Thrust Washer
    GM819600Courtesy of GENERAL MOTORS CORP.
  27. Remove the drive sprocket thrust washer.
    28. Fig 20: Identifying Lockup Shift Assembly & Lockup Mode Shift Fork
    GM819601Courtesy of GENERAL MOTORS CORP.
  28. Remove the lockup shift assembly and lockup mode shift fork.
    29. Fig 21: View Of Lockup Shift Assembly & Lockup Mode Shift Fork
    GM819603Courtesy of GENERAL MOTORS CORP.
  29. Remove the lockup mode shift fork from the lockup shift assembly.
    30. Fig 22: Illustrating Lockup Shift Assembly Components
    GM819604Courtesy of GENERAL MOTORS CORP.
  30. If necessary, disassemble the lockup shift assembly.
    1. Remove the retainer ring from the sleeve.
    2. Remove the hub.
    3. Remove the spring.
    31. Fig 23: Inner Lockup Hub
    GM1549492Courtesy of GENERAL MOTORS CORP.
  31. Remove the inner lockup hub.
    32. Fig 24: Upper Thrust Washer
    GM1549497Courtesy of GENERAL MOTORS CORP.
  32. Remove the upper thrust washer.
    33. Fig 25: Center Bearing Support
    GM1549498Courtesy of GENERAL MOTORS CORP.
  33. Remove the center bearing support.
    34. Fig 26: Bearing, Snap Ring & Support
    GM1549500Courtesy of GENERAL MOTORS CORP.
  34. Using a pair of needle-nose pliers, spread the snap ring in order to remove the bearing from the support, if necessary.
    35. Fig 27: Identifying Magnet
    GM819606Courtesy of GENERAL MOTORS CORP.
  35. Remove the magnet.
    36. Fig 28: Expanded View Of Oil Pump Assembly
    GM819669Courtesy of GENERAL MOTORS CORP.
  36. Remove the oil pump assembly with the hose and screen.
    37. Fig 29: Locating Oil Pump Hose & Screen
    GM819607Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the oil pump hose from the oil pump screen.
  38. Disconnect the oil pump hose from the oil pump.
    39. Fig 30: View Of Shift Fork Shaft
    GM819608Courtesy of GENERAL MOTORS CORP.
  39. Remove the shift fork shaft.
    40. Fig 31: Shift Detent Lever Assembly
    GM819610Courtesy of GENERAL MOTORS CORP.
    NOTE: In order to prevent component damage, properly remove and install the shift detent lever shaft assembly. When removing or installing the shift detent lever shaft assembly, keep the shaft straight and do not tilt. Tilting the shift detent lever shaft assembly in the transfer case housing will break the tip on the end of the shaft.
  40. Remove the shift detent lever assembly.
    • Rotate the high/low shift fork roller from the shift detent lever assembly.
    • Lift straight up on the shift detent lever assembly.
    41. Fig 32: Expanded View Of Shift Detent Lever Assembly
    GM819611Courtesy of GENERAL MOTORS CORP.
  41. If necessary, disassemble the shift detent lever assembly.
    1. Hold the shift detent lever assembly by 1 tab of the spring (3) in a vise.
    2. Rotate the other spring tab and slide the detent lever cam (1) off the shaft.
    3. Remove the sleeve (2).
    4. Push the shaft (4) out of the spring (3).
    42. Fig 33: View Of Mainshaft
    GM819612Courtesy of GENERAL MOTORS CORP.
  42. Remove the mainshaft.
    43. Fig 34: High/Low Range Sleeve & High/Low Range Shift Fork
    GM819613Courtesy of GENERAL MOTORS CORP.
  43. Remove the high/low range sleeve with the high/low range shift fork.
    44. Fig 35: View Of Range Shift Fork & Range Shift Sleeve
    GM819614Courtesy of GENERAL MOTORS CORP.
  44. Remove the range shift fork from the range shift sleeve.
    45. Fig 36: Input Shaft Thrust Washer
    GM819618Courtesy of GENERAL MOTORS CORP.
  45. Remove the input shaft thrust washer.
    46. Fig 37: High/Low Planetary Carrier
    GM819616Courtesy of GENERAL MOTORS CORP.
  46. Remove the high/low planetary carrier.
    47. Fig 38: Inspecting Mainshaft Front Support Bearing
    GM819632Courtesy of GENERAL MOTORS CORP.
  47. Inspect the mainshaft front support bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
  48. Using a brass drift and a hammer, remove the mainshaft front support bearing from the planetary carrier assembly.
    49. Fig 39: Front Output Shaft Assembly
    GM819619Courtesy of GENERAL MOTORS CORP.
  49. Remove the front output shaft assembly.
    50. Fig 40: Removing Front Output Shaft Cup Plug
    GM819620Courtesy of GENERAL MOTORS CORP.
  50. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
    51. Fig 41: View Of Input Seal
    GM849322Courtesy of GENERAL MOTORS CORP.
  51. Using a hammer and a suitable punch, remove the input seal.
    52. Fig 42: Removing Input Shaft Bearing
    GM819622Courtesy of GENERAL MOTORS CORP.
  52. Using a hammer and a brass drift, remove the input shaft bearing from the front case half.
    53. Fig 43: Removing Front Output Shaft Bearing
    GM819623Courtesy of GENERAL MOTORS CORP.
  53. Using a brass drift, remove the front output shaft bearing from the front case half.
    54. Fig 44: Locating Retaining Ring For Annulus Gear
    GM819625Courtesy of GENERAL MOTORS CORP.
  54. Remove the retaining ring for the annulus gear.
    55. Fig 45: Identifying Annulus Gear
    GM819628Courtesy of GENERAL MOTORS CORP.
  55. Remove the annulus gear from the front case half.
    56. Fig 46: View Of Front Case Vent
    GM819664Courtesy of GENERAL MOTORS CORP.
  56. If necessary, remove the vent from the front case half.
    57. Fig 47: View Of Rear Output Shaft In Rear Case Half
    GM819630Courtesy of GENERAL MOTORS CORP.
  57. 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.
    58. Fig 48: Removing Speed Reluctor Wheel With J 22912-01
    GM819633Courtesy of GENERAL MOTORS CORP.
  58. Using a hydraulic press and the J 22912-B  , remove the speed reluctor wheel.

    Do not use the speed reluctor wheel again.

    59. Fig 49: Identifying Rear Output Shaft Bearing Retaining Ring
    GM819634Courtesy of GENERAL MOTORS CORP.
  59. Remove the retaining ring for the rear output shaft bearing.
    60. Fig 50: Pressing Out Rear Output Shaft Bearing
    GM819635Courtesy of GENERAL MOTORS CORP.
  60. Using a hydraulic press, remove the rear output shaft bearing.
    61. Fig 51: View Of Mainshaft Rear Support Bushing
    GM819654Courtesy of GENERAL MOTORS CORP.
  61. Inspect the mainshaft rear support bushing in the rear output shaft for being faulty. Refer to Transfer Case Cleaning and Inspection .
  62. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear support bushing from the rear output shaft. See Special Tools .
    63. Fig 52: Removing Front Output Shaft Rear Bearing With J 26941 & J 23907
    GM819636Courtesy of GENERAL MOTORS CORP.
  63. Using the J 26941  (1) and the J 23907  (2), remove the rear bearing for the front output shaft from the rear case. See Special Tools .
    64. Fig 53: View Of Shift Detent Lever Shaft Seal
    GM819629Courtesy of GENERAL MOTORS CORP.
  64. Remove the seal for the shift detent lever shaft by prying it out from the case.
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