LEMON Manuals: Even more car manuals for everyone
Home >> Isuzu >> 2007 >> i-290 LS, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 85 (Transfer Case - ISUZU T150) >> Repair Instructions >> Transfer Case Disassemble

Transfer Case Disassemble

WARNING: This page is about a different car, the 2007 Isuzu i-370, 2007 GMC Canyon, and 2007 Chevrolet Colorado. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

    Fig 1: Installing J 45759 Onto Transfer Case
    GM908763Courtesy of GENERAL MOTORS CORP.
  1. Install the J 45759  to the transfer case, using 4 suitable bolts. See Special Tools .
    2. Fig 2: Mounting J 45759 Into J 3289-20
    GM908797Courtesy of GENERAL MOTORS CORP.
  2. Mount the J 3289-20  (1) to a sturdy workbench.
  3. Install the J 45759  (2), with the transfer case, into the J 3289-20  (1) and secure with the pivot pin. See Special Tools .
    4. Fig 3: View Of Drain & Fill Plugs
    GM908802Courtesy of GENERAL MOTORS CORP.
  4. Remove the drain plug (15) and the fill plug (10).
  5. Drain the oil.
    6. Fig 4: Identifying Vehicle Speed Sensor (VSS)
    GM908805Courtesy of GENERAL MOTORS CORP.
  6. Remove the vehicle speed sensor and O-ring seal.
    7. Fig 5: Removing Rear Output Shaft Seal
    GM908809Courtesy of GENERAL MOTORS CORP.
  7. Remove the rear output shaft seal.
    8. Fig 6: Locating Vent Hose & Breather Hose
    GM908813Courtesy of GENERAL MOTORS CORP.
  8. Remove the vent hose to the actuator assembly.
  9. Remove the breather hose.
    10. Fig 7: View Of Actuator Assembly
    GM908819Courtesy of GENERAL MOTORS CORP.
  10. Remove the actuator assembly bolts and wire harness bracket.
  11. Remove the actuator assembly and the O-ring seal.
    12. Fig 8: Identifying Connector Bracket Bolt
    GM908823Courtesy of GENERAL MOTORS CORP.
  12. Remove the wiring harness connectors, for the switches, from the switch connector bracket.
  13. Remove the bolt for the connector bracket.
  14. Remove the connector bracket and spacer.
    15. Fig 9: Locating 2/4 Switch Assembly & NEUTRAL Start Switch
    GM908833Courtesy of GENERAL MOTORS CORP.
  15. Remove the 2/4 switch assembly (316) with the copper gasket. The 2/4 switch has the gray wiring harness connector.
  16. Remove the NEUTRAL start switch (307) with the copper gasket. The NEUTRAL start switch has the brown wiring harness connector.
    17. Fig 10: View Of Detent Plugs, Springs & Balls
    GM1542368Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Depending on design levels, this transfer case may or may not have an additional spring nesting inside the high/low shift shaft detent.
  17. Remove the detent plugs, springs and balls.
    18. Fig 11: Identifying Yoke Flange Nut Staking Areas
    GM908841Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to easily remove the nut, ensure the staked areas are completely bent out from the shaft.
  18. Using a suitable punch, bend the stakes out on the yoke flange nut.
    19. Fig 12: View Of J 8614-01 & Yoke Flange Nut
    GM908850Courtesy of GENERAL MOTORS CORP.
  19. Using the J 8614-01  , loosen the yoke flange nut.
    20. Fig 13: View Of Yoke Flange Components
    GM908856Courtesy of GENERAL MOTORS CORP.
  20. Remove the yoke flange nut, the O-ring seal, and the front output yoke flange.
  21. Discard the nut and O-ring seal after removal.
    22. Fig 14: View Of Transfer Case Half Bolts
    GM908863Courtesy of GENERAL MOTORS CORP.
  22. Remove the case half bolts.
    23. Fig 15: Using Soft Face Hammer To Shear Case Half Sealer
    GM908884Courtesy of GENERAL MOTORS CORP.
  23. Using a soft face hammer on the rear case half, shear the case half sealer.
  24. Using a soft face hammer on the end of the front output shaft, separate the case halves.
    25. Fig 16: Separating Rear Case & Front Case
    GM908890Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Hold the rear case half straight to the front case when removing. It may be necessary to reach in and hold the shift forks in position. Watch for pieces to fall out of the cases, if not removed straight and if the shift forks bind.
  25. Carefully remove the rear case half from the front case half. Only the input shaft, with the planetary carrier assembly, will remain in the front case half.
    26. Fig 17: View Of High/Low Shift Fork Assembly
    GM908892Courtesy of GENERAL MOTORS CORP.
  26. Remove the high/low shift fork, with the high/low range sleeve and fork, from the output shaft.
    • The 2/4 synchronizer sleeve may have to be moved forward.
    • The roller on the shift fork may fall off because it is not fastened.
  27. Remove the high/low shift fork from the range sleeve.
    28. Fig 18: Identifying 2/4 Wheel Drive Shift Fork Components
    GM908896Courtesy of GENERAL MOTORS CORP.
  28. Remove the 2/4 wheel drive shift fork, and the 2/4 wheel drive synchronizer sleeve. The roller on the shift fork may fall off because it is not fastened.
  29. Remove the shift fork from the sleeve.
    30. Fig 19: View Of Control Actuator Shaft And The Cam
    GM1208543Courtesy of GENERAL MOTORS CORP.
  30. Remove the control actuator shaft and the cam.
    31. Fig 20: Locating 2/4 Wheel Drive Synchronizer Inserts
    GM908898Courtesy of GENERAL MOTORS CORP.
  31. Remove the 2/4 wheel drive synchronizer inserts from the synchronizer hub.
    32. Fig 21: Identifying Oil Pump Pick-Up Tube Retaining Bolt
    GM908899Courtesy of GENERAL MOTORS CORP.
  32. Remove the bolt retaining the oil pump pick-up tube.
    33. Fig 22: Expanded View Of Rear Output Shaft Rear Bearing Retaining Ring
    GM908902Courtesy of GENERAL MOTORS CORP.
  33. Using snap ring pliers, squeeze together the retaining ring for the rear output shaft rear bearing.
  34. Using a soft face hammer on the rear output shaft, remove the rear output shaft assembly until the rear output shaft bearing is just out of the case.
    35. Fig 23: Identifying Front Output Shaft And The Drive Chain
    GM908928Courtesy of GENERAL MOTORS CORP.
  35. Remove the front output shaft and the drive chain.
    36. Fig 24: View Of Oil Deflector
    GM908934Courtesy of GENERAL MOTORS CORP.
  36. Remove the bolts and the oil deflector.
  37. Remove the rear output shaft assembly completely from the rear case half.
    38. Fig 25: Removing Speed Sensor Reluctor Wheel
    GM908942Courtesy of GENERAL MOTORS CORP.
  38. Remove the rear output shaft retaining ring.
  39. Remove the speed sensor reluctor wheel.
    40. Fig 26: View Of Rear Output Shaft Bearing & Outer Retaining Ring
    GM908947Courtesy of GENERAL MOTORS CORP.
  40. Remove the rear output shaft bearing.
  41. Remove the rear output shaft bearing outer retaining ring.
    42. Fig 27: Identifying Oil Pump Assembly With Suction Hose
    GM908952Courtesy of GENERAL MOTORS CORP.
  42. Remove the oil pump assembly with suction hose.
    43. Fig 28: View Of Oil Pump Components
    GM909424Courtesy of GENERAL MOTORS CORP.
  43. Remove the oil pump suction hose from the oil pump.
  44. Remove the oil pump suction hose from the oil pump screen.
    45. Fig 29: Locating Drive Sprocket Retaining Ring & Thrust Washer
    GM908953Courtesy of GENERAL MOTORS CORP.
  45. Remove the drive sprocket retaining ring.
  46. Remove the drive sprocket thrust washer.
    47. Fig 30: Expanded View Of Synchronizer Blocking Ring, Middle Ring & Inner Ring
    GM908957Courtesy of GENERAL MOTORS CORP.
  47. Remove the drive sprocket.
  48. Remove the synchronizer blocking ring, middle ring and inner ring.
    49. Fig 31: Identifying Synchronizer Hub Springs
    GM908962Courtesy of GENERAL MOTORS CORP.
  49. Remove the springs from the synchronizer hub.
    50. Fig 32: View Of Synchronizer Hub Retaining Ring
    GM908967Courtesy of GENERAL MOTORS CORP.
  50. Remove the synchronizer hub retaining ring.
    51. Fig 33: Using J 22912-01 To Press Out Synchronizer Hub From The Rear Output Shaft
    GM908972Courtesy of GENERAL MOTORS CORP.
  51. Using a hydraulic press and the J 22912-B  , remove the synchronizer hub from the rear output shaft.
    52. Fig 34: Identifying Rear Output Shaft Front Support Bearing
    GM908978Courtesy of GENERAL MOTORS CORP.
  52. Remove the rear output shaft front support bearing from inside of the input shaft.
    53. Fig 35: Removing Input Shaft Seal With J 23907 & J 45278
    GM908975Courtesy of GENERAL MOTORS CORP.
  53. Using the J 23907  (1) and the J 45278  (2), remove the input shaft seal. See Special Tools .
    • There is not a shoulder to prevent the seal from going into the case.
    • Turn, and hold the J 45278  (2) under the seal for removal. See Special Tools .
    54. Fig 36: Spreading Planetary Carrier Bearing Retaining Ring
    GM908980Courtesy of GENERAL MOTORS CORP.
  54. Using a large pair of snap ring pliers, spread the retaining ring for the planetary carrier bearing.
    55. IMPORTANT: Ensure the snap ring pliers do not catch on the ribs in the case. The retaining ring must be completely spread open.
  55. While the retaining ring is spread, use a soft face hammer on the input shaft to remove the planetary carrier assembly.
    56. Fig 37: Identifying Planetary Carrier Low Gear Components
    GM908983Courtesy of GENERAL MOTORS CORP.
  56. For assembly purposes, mark the relationship of the planetary carrier low gear to the planetary carrier.
  57. Remove the retaining ring for the planetary carrier low gear.
  58. Remove the planetary carrier low gear.
    59. Fig 38: View Of Input Shaft In Planetary Carrier Assembly
    GM908987Courtesy of GENERAL MOTORS CORP.
  59. Remove the input shaft from the planetary carrier assembly.
    60. Fig 39: Locating Input Shaft Thrust Bearing
    GM908999Courtesy of GENERAL MOTORS CORP.
  60. Remove the input shaft thrust bearing.
    61. Fig 40: Identifying Planetary Carrier Bearing Retaining Ring
    GM909004Courtesy of GENERAL MOTORS CORP.
  61. Remove the planetary carrier assembly bearing retaining ring.
    62. Fig 41: Pressing Out Planetary Carrier Bearing
    GM909011Courtesy of GENERAL MOTORS CORP.
  62. Using a hydraulic press with the J 45933-1 (1) of the J 45933  and the J 22912-B  (2), remove the planetary carrier bearing. See Special Tools .
    63. Fig 42: View Of J 26941 & J 23907
    GM909084Courtesy of GENERAL MOTORS CORP.
  63. Using the J 26941  (1) and the J 23907  (2), remove the input shaft bearing from the planetary carrier. See Special Tools .
    64. Fig 43: Locating Annulus Gear Spiral Retaining Ring
    GM909088Courtesy of GENERAL MOTORS CORP.
  64. Remove the annulus gear spiral retaining ring.
    65. Fig 44: View Of Annulus Gear
    GM909147Courtesy of GENERAL MOTORS CORP.
  65. Remove the annulus gear.
    66. Fig 45: Locating Annulus Gear Damper
    GM909152Courtesy of GENERAL MOTORS CORP.
  66. Remove the annulus gear damper.
    67. Fig 46: Identifying Carrier Bearing Outer Retaining Ring
    GM909246Courtesy of GENERAL MOTORS CORP.
  67. Remove the carrier bearing outer retaining ring from the front case.
    68. Fig 47: View Of Breather Baffle & Retaining Bolt
    GM909158Courtesy of GENERAL MOTORS CORP.
  68. If necessary, remove the breather baffle and bolt.
    69. Fig 48: View Of Front Output Shaft Front Bearing Retaining Ring
    GM909162Courtesy of GENERAL MOTORS CORP.
  69. Remove the front output shaft front bearing retaining ring.
    70. Fig 49: Identifying Front Output Shaft Seal
    GM909170Courtesy of GENERAL MOTORS CORP.
  70. Remove the front output shaft seal.
  71. Remove the front case half from the J 45759  . See Special Tools .
    72. Fig 50: Removing Front Output Shaft Bearing Using J 8092 & J 46199
    GM909174Courtesy of GENERAL MOTORS CORP.
  72. Inspect the front output shaft bearing for being faulty. Refer to Cleaning and Inspection .
  73. Using the J 8092  (1) and the J 46199  (2), remove the front output shaft front bearing. See Special Tools .
  74. Discard the bearing after removal.
    75. Fig 51: View Of Oil Pump Retaining Ring
    GM909185Courtesy of GENERAL MOTORS CORP.
  75. Remove the oil pump retaining ring from the rear case half.
    76. Fig 52: Installing J 23907 & J 29369-2 In Rear Case
    GM909199Courtesy of GENERAL MOTORS CORP.
  76. Using the J 23907  (1) and the J 29369-2  (2), remove the front output shaft rear bearing from the rear case half. Do not use the bearing after removal. See Special Tools .
    77. Fig 53: Locating Control Actuator Shaft Seal
    GM909203Courtesy of GENERAL MOTORS CORP.
  77. Remove the control actuator shaft seal from the rear case.
    78. Fig 54: View Of J 45933-4 & J 45933 Installed In Rear Case
    GM909479Courtesy of GENERAL MOTORS CORP.
  78. Inspect the rear bushing for being faulty. Refer to Cleaning and Inspection .
    79. IMPORTANT:
    • Use the thrust bearing between the J 45933-4 (2) and a washer.
    • Ensure the threads, of the threaded shaft, on the J 45933  are lubricated with the supplied lubricant. See Special Tools .
  79. If the rear bushing is faulty, remove the bushing using the J 45933-4 (2) and the J 45933-3 (1) of the J 45933  . See Special Tools .
    80. Fig 55: View Of Shift Shaft Plugs
    GM909481Courtesy of GENERAL MOTORS CORP.
  80. If necessary, remove the shift shaft plugs.
    81. Fig 56: Locating Vent/Breather Hose Pipes
    GM909477Courtesy of GENERAL MOTORS CORP.
  81. If necessary, remove the vent or breather hose pipes.
    82. Fig 57: Identifying Control Actuator Shaft Bushing
    GM909473Courtesy of GENERAL MOTORS CORP.
  82. If necessary, remove the control actuator shaft bushing.
    83. Fig 58: View Of Shift Rail Retaining Ring
    GM909206Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Only disassemble the shift forks if components require replacement. Refer to Cleaning and Inspection .
  83. Disassemble the high/low shift fork by compressing the spring in a vise.
  84. Remove the retaining ring from the shift shaft.
  85. Remove the shift fork assembly from the vise and remove the shift block.
    86. Fig 59: View Of Shift Rail Inner Retaining Ring
    GM909209Courtesy of GENERAL MOTORS CORP.
  86. Using a socket and vise, compress the spring in the high/low shift block. Use a small enough diameter socket to allow removal of the inner retaining ring.
  87. Remove the inner retaining ring from the shift block.
    88. Fig 60: View Of Shift Block Components
    GM909212Courtesy of GENERAL MOTORS CORP.
  88. Remove the shift block from the vise.
  89. Remove the spring seat (252), the spring (253) and the block collar (254) from the shift block (256).
    90. Fig 61: Locating Roll Pin On High/Low Shift Fork
    GM909216Courtesy of GENERAL MOTORS CORP.
  90. Remove the roll pin from the high/low shift fork.
  91. Remove the shift fork from the shift shaft.
    92. Fig 62: Locating 2/4 Shift Fork Retaining Ring
    GM909221Courtesy of GENERAL MOTORS CORP.
  92. Disassemble the 2/4 shift fork by compressing the spring in a vise.
  93. Remove the retaining ring from the shift shaft.
    94. Fig 63: View Of 2/4 Shift Fork And Spring On The Shift Shaft
    GM909223Courtesy of GENERAL MOTORS CORP.
  94. Remove the 2/4 shift fork and spring from the shift shaft. The shift block is serviced with the shift shaft.
scientia non olet · About LEMON Manuals