Transmission

Transfer Case - AAM

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

Specification
Application Metric English
Transfer Case Bracket-to-Engine Bolts 22 N.m 16 lb ft
Transfer Case Bracket-to-Rear Extension Housing Bolts 58 N.m 43 lb ft
Transfer Case-to-Transmission Bolts 110 N.m 81 lb ft
Transfer Case-to-Transmission Bolts- RPO MXE
 First pass 100 N.m 74 lb ft
 Second pass 60 degrees
Transfer Case Housing-to-Rear Extension Housing Bolts
 First pass 25 N.m 18 lb ft
 Second pass 130 degrees
Transfer Case Oil Fill Plug 40 N.m 30 lb ft
Transfer Case Oil Drain Plug 40 N.m 30 lb ft
Transfer Case Rear Output Shaft Flange Bolts 35 N.m 25 lb ft
Transfer Case Vent 25 N.m 18 lb ft

APPROXIMATE FLUID CAPACITIES

Approximate Fluid Capacities

Specification
Application Metric English
Transfer Case Oil GM P/N 19256084 (Canadian P/N
0.65 L 0.69 qt
19256085)

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United Sates Canada
Transfer Case Oil Lubricant 19256084 19256085
Intermediate Shaft Output
Lubricant 1051344 00993037
Splines
Transfer Case Rear Threadlocker 89021297 10953488
Extension Housing Bolts
Transfer Case Rear
Extension Housing Bolt Cleaner 88862650 88901247
Holes
Vent Hose Connector
Sealant 12346004 10953480
Threads

COMPONENT LOCATOR
TRANSFER CASE DISASSEMBLED VIEW

Transfer Case Components

Fig. 1: Transfer Case Components (MH4)

Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

1 Transmission-to-Transfer Case O-ring Seal
 2 Input Shaft Front (outer) Seal
3 Transfer Case Vent Hose Connector
4 Transfer Case Housing
5 Transfer Case Rear Extension Housing-to-Transfer Case Seal
6 Transfer Case Vent Baffle
7 Input Shaft Front (inner) Seal
8 Input Shaft Front Bearing Race
9 Input Shaft Front Bearing
10 Input Shaft
11 Transfer Case Vent Baffle Bolt
12 Idler Shaft Front Bearing
13 Idler Shaft Front Bearing Race
14 Idler Shaft Front Bearing Shim
15 Input Shaft Rear Bearing
16 Input Shaft Rear Bearing Race
17 Input Shaft Rear Bearing Shim
18 Input Shaft Bearing Retainer Rear Seal
19 Rear Extension Housing
20 Transfer Case-to-Rear Extension Housing Bolt
21 Intermediate Shaft Seal
22 Transfer Case Fill Plug
23 Transfer Case Fill Plug Sealing Washer
24 Transfer Case-to-Rear Extension Housing Locating Pin
25 Idler Shaft Rear Bearing Shim
26 Idler Shaft Rear Bearing Race
27 Idler Shaft Rear Bearing
28 Idler Shaft
29 Transfer Case Seal
30 Intermediate Shaft O-ring Seal - Second Design
31 Intermediate Shaft Dirt Deflector - Model Dependent
32 Intermediate Shaft Assembly Retaining Ring
33 Intermediate Shaft Bearing Retaining Ring
34 Intermediate Shaft Bearing
35 Intermediate Shaft
36 Rear Output Shaft Housing O-ring Seal
37 Rear Output Shaft Shim
38 Rear Output Shaft
39 Rear Output Shaft Bearing
40 Rear Output Shaft Bearing Race
41 Rear Output Shaft Housing
42 Rear Output Shaft Bearing Spacer
43
 Rear Output Shaft Bearing Race
44 Rear Output Shaft Bearing
45 Rear Output Drive Gear Nut
46 Rear Output Shaft Seal
47 Rear Output Shaft Housing Bolt
48 Transfer Case Drain Plug
49 Transfer Case Drain Plug Sealing Washer

Transfer Case Seal View

Fig. 2: Transfer Case Seal View

Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

1 Transfer Case-to-Transmission Seal

Transfer Case Mounting

Fig. 3: Transfer Case Mounting Components (MH4)
Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

1 Transaxle Brace
2 Transaxle Brace Bolt
3 Transfer Case Bracket-to-Engine Bolt
4 Transfer Case Bracket Bolt
5 Transfer Case Bracket
6 Transfer Case
7 Transfer Case-to-Transmission Bolt
8 Transaxle Brace-to-Engine Bolt

Vent Hose Assembly

Fig. 4: Vent Hose Assembly Components
Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

1 Vent Hose Assembly
2 Strap
3 Bolt

DIAGNOSTIC INFORMATION AND PROCEDURES

SYMPTOMS - TRANSFER CASE

Strategy Based Diagnostics

Review the system operations in order to familiarize yourself with the system functions. Refer to Transfer
Case Disassembled View, Transfer Case Description and Operation, and DESCRIPTION AND
OPERATION . All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a
uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a
system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed
explanation, refer to Strategy Based Diagnosis .

Visual/Physical Inspection

 Inspect for aftermarket devices, which could affect the operation of the vehicle. Refer to Checking
Aftermarket Accessories .
 Inspect the easily accessible or visible system components for obvious damage or conditions, which could
cause the symptom.
 Inspect for the correct lubricant levels and the proper viscosities.
 Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed,
road conditions, ambient temperature, and other specifics.
 Compare the driving characteristics or sounds, if applicable, to a known good vehicle and ensure you are
not trying to correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:

 Diagnostic System Check - Vehicle

 Noisy in Drive
 Noisy When Coasting
 Intermittent Noise
 Constant Noise
 Transfer Case Leak Diagnosis

NOISY IN DRIVE

Noisy in Drive
Cause Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Inspect the transfer case for leaks, repair as required.
Low gear oil level Refer to Transfer Case Leak Diagnosis, and
Adhesives, Fluids, Lubricants, and Sealers.
Replace the gear oil. Refer to Adhesives, Fluids,
Incorrect gear oil in the transfer case
Lubricants, and Sealers.
Water or contamination within the lubricant Replace the lubricant and flush the transfer case of
the contaminated fluid.
Replace propeller shaft assembly. Refer to
Worn propeller shaft constant velocity joints
Propeller Shaft Replacement .
Worn or noisy wheel bearings Replace the wheel bearings as required.
Worn axle shaft constant velocity joints Replace the constant velocity joints, as required.
Worn bearing in the differential assembly Repair or replace the assembly.
Bearing noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A grinding noise that occurs at a specific
2. Identify the location of the noise using the J
engine speed, regardless of transmission gear,
39570 Chassis Ears.
is not within the transfer case.
3. If the noise continues, repair or replace
 A grinding noise that changes as a
components, as required.
transmission shift occurs is not within the
transfer case.
 A grinding noise that changes as vehicle
speed changes may be also caused by worn
wheel bearings.
 A grinding noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.
Gear set whine noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A whine noise that occurs at a specific engine
2. Identify the location of the noise using the J
speed, regardless of transmission gear, is not
39570 Chassis Ears.
within the transfer case.
3. If the noise continues, repair or replace
 A whine noise that changes as a transmission
components, as required.
shift occurs is not within the transfer case.
 A whine noise that changes as vehicle speed
changes may be also caused by worn wheel
bearings.
 A whine noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.

NOISY WHEN COASTING

Noisy When Coasting

Cause Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Inspect the transfer case for leaks, repair as required.
Low gear oil level Refer to Transfer Case Leak Diagnosis, and
Adhesives, Fluids, Lubricants, and Sealers.
Replace the gear oil. Refer to Adhesives, Fluids,
Incorrect gear oil in the transfer case.
Lubricants, and Sealers.
Worn propeller shaft constant velocity joints Replace the propeller shaft assembly. Refer to
Propeller Shaft Replacement
Worn axle shaft constant velocity joints Replace the constant velocity joints, as required.
Worn bearing in the differential assembly Repair or replace the assembly as required.
Bearing noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A grinding noise that occurs at a specific
2. Identify the location of the noise using the J
engine speed, regardless of transmission gear,
39570 Chassis Ears.
is not within the transfer case.
3. If the noise continues, repair or replace
 A grinding noise that changes as a
components, as required.
transmission shift occurs is not within the
transfer case.
 A grinding noise that changes as vehicle
speed changes may be also caused by worn
wheel bearings.
 A grinding noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.
Gear set whine noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A whine noise that occurs at a specific engine
2. Identify the location of the noise using the J
speed, regardless of transmission gear, is not
39570 Chassis Ears.
within the transfer case.
3. If the noise continues, repair or replace
 A whine noise that changes as a transmission
components, as required
shift occurs is not within the transfer case.
 A whine noise that changes as vehicle speed
changes may be also caused by worn wheel
bearings.
 A whine noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.

INTERMITTENT NOISE

Intermittent Noise
Cause Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Incorrect gear oil in the transfer case. Replace the gear oil. Refer to Adhesives, Fluids,
Lubricants, and Sealers.
Transfer case bearing or rear drive axle clutch Confirm noise is coming from the transfer case or
module. the rear drive axle clutch module. Repair as
A chatter or racheting type noise during hard required.
acceleration on tight turns.

CONSTANT NOISE

Constant Noise
 Cause Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Low gear oil level Inspect the transfer case for leaks, repair as required.
Refer to Transfer Case Leak Diagnosis, and
Adhesives, Fluids, Lubricants, and Sealers.
Replace the gear oil. Refer to Adhesives, Fluids,
Incorrect gear oil in the transfer case
Lubricants, and Sealers.
Worn propeller shaft constant velocity joints Replace the propeller shaft assembly. Refer to
Propeller Shaft Replacement .
Worn bearing in the differential assembly Repair or replace the assembly as required.
Bearing noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A grinding noise that occurs at a specific
2. Identify the location of the noise using the J
engine speed, regardless of transmission gear,
39570 Chassis Ears.
is not within the transfer case.
3. If the noise continues, repair or replace
 A grinding noise that changes as a
components, as required.
transmission shift occurs is not within the
transfer case.
 A grinding noise that changes as vehicle
speed changes may be also caused by worn
wheel bearings.
 A grinding noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.
Gear set whine noise within the transfer case 1. Inspect for the proper fluid level. Fill, as
required.
 A whine noise that occurs at a specific engine
2. Identify the location of the noise using the J
speed, regardless of transmission gear, is not
39570 Chassis Ears.
within the transfer case.
3. If the noise continues, repair or replace
 A whine noise that changes as a transmission
components, as required.
shift occurs is not within the transfer case.
 A whine noise that changes as vehicle speed
changes may be also caused by worn wheel
bearings.
 A whine noise that changes as the vehicle
turns may also be caused by worn wheel
bearings and/or tires.

TRANSFER CASE LEAK DIAGNOSIS

Transfer Case Leak Diagnosis

Cause Correction

DEFINITION: A visible indication of an external fluid leak from the transfer case.
Review the Symptoms - Transfer Case and perform the necessary inspections. See below for suggested
diagnostic method(s).
Special Tools

 GE 28431-6 Fluorescent Oil Dye

 GE 28428-E High Intensity Black Light Kit

For equivalent regional tools, refer to Special Tools.

Fluorescent Dye Method

1. Add GE 28431-6 Fluorescent dye to the transmission or transfer case to determine the source of
the leak.
2. Operate the vehicle.
3. Inspect for the presence of dye within the oil leak using the GE 28428-E High Intensity Black
Light Kit. A presence or non-presence of dye within the oil leak will indicate which component is
the source of the leak.

Powder Method

CAUTION:
Do not clean using brake cleaner or other reactive solvents as these solvents can damage
rubber gaskets, seals and bushings.

1. Thoroughly clean the suspected leak area using a rag.

2. Apply an aerosol type leak tracing powder to the suspected leak area.

NOTE:
Do not drive the vehicle on the freeway as this will splatter oil inhibiting leak diagnosis.

3. Operate the vehicle for 15-20 minutes under city driving conditions until normal operating
temperatures are reached.
4. Shut OFF the engine.
5. Inspect the suspected leak area.
6. Trace the leak path through the powder in order to find the source of the leak.
Drain plug or fill plug leak 1. Inspect for dirty, worn, scored sealing
surfaces, or missing drain and/or fill plug
sealing washers.
2. Replace as required.
Restricted or damaged ventilation hose assembly Replace the ventilation hose assembly, as required.
Leaking at the transfer case left side weep hole Replace components as required.
If the leak is transmission or O-ring related, do not
 A transmission oil leak at the transfer case replace the transfer case input shaft seals.
weep hole area is caused by the transmission
right side drive shaft seal.
  A gear oil leak at the transfer case weep hole
area is caused by the transfer case input shaft
front (inner) seal.
Leaking at the transfer case right side weep hole
A transmission or gear oil leak at the transfer case
Replace the input shaft seal.
right side weep hole is caused by the input shaft
seal located in the rear extension housing.
Leaking ATF at the right side axle shaft-to- Replace the intermediate shaft seal located in the
intermediate shaft bearing location rear extension housing.
Leaking at rear output shaft area Inspect and replace the rear output shaft seal as
A leak at rear output shaft area is caused by either required.
the rear output shaft seal or the rear output shaft The O-ring is not serviceable on AAM transfer case.
housing O-ring seal.
Leaking at transaxle assembly-to-transfer case
interface

 A transmission oil leak at the transmission-to- NOTE:

transfer case interface may be caused by the If the leak is transmission or O-ring related,
transmission-to-transfer case o-ring seal. do not replace the transfer case input shaft
seals.
 A transmission oil leak at the transfer case
weep hole area is caused by the transmission 1. Identify the type of oil leak.
right side drive shaft seal.
2. Replace components as required.
 A gear oil leak at the transfer case weep hole
area is caused by the transfer case input shaft
front (inner) seal.
Disassemble and replace the transfer case-to-rear
Case half seam leak AAM
extension housing O-ring seal.
Leaking through case  Inspect for a cracked case.
 Inspect for case porosity.

REPAIR INSTRUCTIONS - ON VEHICLE

TRANSFER CASE FLUID REPLACEMENT

Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
 Fig. 5: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

NOTE:  When performing the following procedure, use only hand tools to
remove and install the drain and fill plugs.
 Ensure that an approved drain pan is used when draining the transfer
case.

2. Remove and DISCARD the oil drain plug (1) and seal.
 Fig. 6: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

3. Remove and DISCARD the fill plug (1) and seal.

4. Allow the transfer case to drain completely.

Installation Procedure
 Fig. 7: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

1. Install a NEW drain plug (1) and seal and tighten to 50 (37 lb ft).
2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
 Fig. 8: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

3. Install a NEW fill plug (1) and seal and tighten to 50 (37 lb ft).

DRAIN PLUG REPLACEMENT

Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
 Fig. 9: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

NOTE:  When performing the following procedure, use only hand tools to
remove and install the drain and fill plugs.
 Ensure that an approved drain pan is used when draining the transfer
case.

2. Remove and DISCARD the oil drain plug (1) and seal.
 Fig. 10: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

3. Remove and DISCARD the fill plug (1) and seal.

4. Allow the transfer case to drain completely.

Installation Procedure
 Fig. 11: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

1. Install a NEW drain plug (1) and seal and tighten to 50 (37 lb ft).
2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
 Fig. 12: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

3. Install a NEW fill plug (1) and seal and tighten to 50 (37 lb ft).

FILL PLUG REPLACEMENT

Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
 Fig. 13: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

2. Remove and DISCARD the fill plug (1) and seal.

Installation Procedure
 Fig. 14: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

1. Install a NEW fill plug (1) and seal and tighten to 50 (37 lb ft).
2. Lower the vehicle.

FRONT OUTPUT SHAFT SEAL REPLACEMENT

Special Tools

 DT-50768 Seal Installer

 J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
 Fig. 15: Wheel Drive Shaft Seal And Dust Deflector
Courtesy of GENERAL MOTORS COMPANY

2. Remove the dust deflector (1) first using a prying type tool and then remove the seal (2) by installing a
sheet metal screw into surface and removing with suitable pliers.
3. Discard the seal assembly (1,2).

Installation Procedure
 Fig. 16: Seal And Special Installer Tool
Courtesy of GENERAL MOTORS COMPANY

1. Install the New seal assembly (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
2. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

FRONT WHEEL DRIVE INTERMEDIATE SHAFT REPLACEMENT

Special Tools

 DT-113-2-A Holder
 DT-622-A Transmission Bracket
 DT-49104 Protective Collar
 DT-50768 Seal Installer
 J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the transfer case from the vehicle. Refer to Transfer Case Replacement.
 Fig. 17: Transmission Bracket, Transfer Case And Holder
Courtesy of GENERAL MOTORS COMPANY

2. Secure the transfer case (3) in DT-113-2-A holder (1), using the DT-622-A bracket (2).
 Fig. 18: Wheel Drive Shaft Seal And Dust Deflector
Courtesy of GENERAL MOTORS COMPANY

3. Remove the dust deflector (1) first using a prying type tool and then remove the seal (2) by installing a
sheet metal screw into surface and removing with suitable pliers.
4. Discard the seal assembly (1,2).
 Fig. 19: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

5. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 20: Transfer Case Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

6. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.
7. Remove the bearing, if necessary. Refer to front wheel drive intermediate shaft in Transfer Case
Disassemble.

Installation Procedure

1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in Transfer Case Assemble.
 Fig. 21: View Of Installing Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

2. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft
using the DT-48076 installer (3) and a rubber mallet.
3. Remove the DT-49104 protective collar (1).
 Fig. 22: Intermediate Shaft Output Splines
Courtesy of GENERAL MOTORS COMPANY

4. Apply grease to the output splines (1) of the intermediate shaft.

 Fig. 23: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 24: Seal And Special Installer Tool
Courtesy of GENERAL MOTORS COMPANY

6. Install the New seal assembly (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
7. Install the transfer case in the vehicle. Refer to Transfer Case Replacement.

REAR OUTPUT SHAFT SEAL REPLACEMENT

Fig. 25: Rear Output Shaft Seal
Courtesy of GENERAL MOTORS COMPANY

Rear Output Shaft Seal Replacement

Callout Component Name
Preliminary Procedures

1. Remove the propeller shaft. Refer to Propeller Shaft Replacement .

2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement.
Dust Shield
Procedure
Install the dust shield using DT-49095 installer.
1
Special Tools
DT-49095 Seal Installer
For equivalent regional tools, refer to Special Tools.
Rear Output Shaft Seal
Procedure
Install the shaft seal using DT-49097 installer and DT-49061 cone.

Special Tools
2
 DT-49061 Entry Cone
 DT-49097 Seal Installer
 For equivalent regional tools, refer to Special Tools.

INTERMEDIATE DRIVE SHAFT DIRT DEFLECTOR REPLACEMENT

Special Tools

 DT-50768 Seal Installer

 J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

Fig. 26: Wheel Drive Shaft Seal And Dust Deflector

Courtesy of GENERAL MOTORS COMPANY

2. Remove the dust deflector (1) first using a prying type tool and then remove the seal (2) by installing a
sheet metal screw into surface and removing with suitable pliers.
3. Discard the seal assembly (1,2).
Installation Procedure

Fig. 27: Seal And Special Installer Tool

Courtesy of GENERAL MOTORS COMPANY

1. Install the New seal assembly (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
2. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - CASE SIDE

Removal Procedure

1. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
 Fig. 28: Intermediate Shaft O-Ring (Second Design)
Courtesy of GENERAL MOTORS COMPANY

2. Remove the second design intermediate shaft O-ring (3), as required.

Installation Procedure
 Fig. 29: Intermediate Shaft O-Ring (Second Design)
Courtesy of GENERAL MOTORS COMPANY

1. Install the second design intermediate shaft O-ring (3), as required.

2. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

FRONT WHEEL DRIVE INTERMEDIATE SHAFT BEARING REPLACEMENT

Special Tools

 DT-113-2-A Holder
 DT-622-A Transmission Bracket
 DT-49104 Protective Collar
 DT-50768 Seal Installer
 J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the transfer case from the vehicle. Refer to Transfer Case Replacement.
 Fig. 30: Transmission Bracket, Transfer Case And Holder
Courtesy of GENERAL MOTORS COMPANY

2. Secure the transfer case (3) in DT-113-2-A holder (1) , using the DT-622-A bracket (2) .
 Fig. 31: Wheel Drive Shaft Seal And Dust Deflector
Courtesy of GENERAL MOTORS COMPANY

3. Remove the dust deflector (1) first using a prying type tool and then remove the seal (2) by installing a
sheet metal screw into surface and removing with suitable pliers.
4. Discard the seal assembly (1,2).
 Fig. 32: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

5. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 33: Transfer Case Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

6. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.
7. Remove the bearing, if necessary. Refer to front wheel drive intermediate shaft in Transfer Case
Disassemble.

Installation Procedure

1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in Transfer Case Assemble.
 Fig. 34: View Of Installing Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

2. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft
using the DT-48076 installer (3) and a rubber mallet.
3. Remove the DT-49104 protective collar (1).
 Fig. 35: Intermediate Shaft Output Splines
Courtesy of GENERAL MOTORS COMPANY

4. Apply grease to the output splines (1) of the intermediate shaft.

 Fig. 36: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 37: Seal And Special Installer Tool
Courtesy of GENERAL MOTORS COMPANY

6. Install the New seal assembly (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
7. Install the transfer case in the vehicle. Refer to Transfer Case Replacement.

TRANSFER CASE REPLACEMENT

Removal Procedure

1. Remove the propeller shaft. Refer to Propeller Shaft Replacement .

2. Drain the oil from the transmission. Refer to Transmission Fluid Drain and Fill .
3. Remove the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
4. Remove the exhaust front pipe. Refer to , Exhaust Front Pipe Replacement (LUK) , Exhaust Front
Pipe Replacement (LTG AWD) .
5. Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement
(AWD) .
 Fig. 38: Transfer Case Vent Hose, Strap And Bolt
Courtesy of GENERAL MOTORS COMPANY

6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).
 Fig. 39: Transfer Case Support Bracket-To-Transfer Case Bolts
Courtesy of GENERAL MOTORS COMPANY

7. Remove the transfer case support bracket-to-transfer case bolts (2).

8. Remove the transfer case support bracket-to-engine bolts (3).
9. Remove the support bracket (1).
10. Support the transfer case with a suitable jack, and secure with suitable straps.
 Fig. 40: Transfer Case-To-Transmission Bolts
Courtesy of GENERAL MOTORS COMPANY

11. Remove the remaining five transfer case-to-transmission bolts (1).

12. Separate the transfer case from the transmission and remove the transfer case.

Installation Procedure
 Fig. 41: Identifying Transfer Case-To-Transmission O-Ring
Courtesy of GENERAL MOTORS COMPANY

1. Clean the contact surfaces between the transfer case and the transmission. Install a new transfer case-to-
transmission O-ring (1).
 Fig. 42: Transfer Case-To-Transmission Bolts
Courtesy of GENERAL MOTORS COMPANY

2. Support the transfer case with a suitable jack, and secure with suitable straps.
3. Raise and align the transfer case in the correct position in relation to the transmission.
4. Install the transfer case to the transmission.

CAUTION: Refer to Fastener Caution .

5. Install the five transfer case-to-transmission bolts (1), then tighten the bolts to 110 (81 lb ft).
 Fig. 43: Transfer Case Support Bracket-To-Transfer Case Bolts
Courtesy of GENERAL MOTORS COMPANY

6. Install the support bracket (1).

7. Install the transfer case support bracket-to-transfer case bolts (2).
8. Install the transfer case support bracket-to-engine bolts (3).
9. Install the support bracket between the transfer case and the engine carefully in three steps to avoid
breakage.
1. Tighten the support bracket-to-transfer case bolts (2) the first time to 5 (44 lb in).
2. Tighten the support bracket-to-engine bolts (3) to 60 (44 lb ft).
3. Tighten the support bracket-to-transfer case bolts (2) the second time to 60 (44 lb ft).
10. Install the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement (AWD) .
 Fig. 44: Transfer Case Vent Hose, Strap And Bolt
Courtesy of GENERAL MOTORS COMPANY

11. Install the transfer case vent hose (2), strap (1), and bolt (3).
12. Tighten the transfer case vent hose bolt, if equipped, to 22 (17 lb ft).
13. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
14. Install the propeller shaft. Refer to Propeller Shaft Replacement .
15. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LUK) , Exhaust Front Pipe
Replacement (LTG AWD) .
16. Check the fluid level in the transfer case. Refer to Transfer Case Fluid Replacement.
17. Fill the transmission with oil. Refer to Transmission Fluid Drain and Fill .
18. Fill the transfer case fluid. Refer to Transfer Case Fluid Replacement.

INPUT SHAFT SEAL REPLACEMENT

Removal Procedure

1. Remove the transfer case from the vehicle. Refer to Transfer Case Replacement.
 Fig. 45: Identifying Transfer Case-To-Transmission O-Ring
Courtesy of GENERAL MOTORS COMPANY

2. Remove and DISCARD the transfer case-to-transmission seal (1).

Installation Procedure
 Fig. 46: Identifying Transfer Case-To-Transmission O-Ring
Courtesy of GENERAL MOTORS COMPANY

1. Install the NEW transfer case-to-transmission seal (1).

2. Install the transfer case in the vehicle. refer to Transfer Case Replacement.

REPAIR INSTRUCTIONS - OFF VEHICLE

TRANSFER CASE DISASSEMBLE

Oil Drain Plug Removal

Fig. 47: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

Remove and discard the oil drain plug (1) and seal.

Oil Fill Plug Removal

Fig. 48: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

Remove and discard the oil fill plug (1) and seal.

Transfer Case Vent Removal

Fig. 49: View Of Transfer Case Vent
Courtesy of GENERAL MOTORS COMPANY

Remove the transfer case vent hose connector (1), as required.

Transfer Case-to-Transmission Seal Removal

Fig. 50: Identifying Transfer Case-To-Transmission O-Ring
Courtesy of GENERAL MOTORS COMPANY

Remove and discard the transfer case-to-transmission seal (1).

Locating Bushing Removal

Fig. 51: View Of Transfer Case Location Bushing
Courtesy of GENERAL MOTORS COMPANY

Remove the transfer case locating bushing (1), using multi-grip pliers as required - Model Dependent.

Front Wheel Drive Intermediate Shaft Removal

Special Tools

 DT-113-2-A Holder
 DT-622-A Transmission Bracket

For equivalent regional tools, refer to Special Tools.

 Fig. 52: Transmission Bracket, Transfer Case And Holder
Courtesy of GENERAL MOTORS COMPANY

1. Secure the transfer case (3) in DT-113-2-A holder (1) , using the DT-622-A bracket (2) .
 Fig. 53: View Of Shaft Dirt Deflector & Grease Seal Assembly
Courtesy of GENERAL MOTORS COMPANY

2. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the dirt
deflector and remove with suitable pliers.
3. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool
and then remove the outer portion by installing a sheet metal screw into surface and removing with
suitable pliers.
4. Discard the seal assembly (1).
 Fig. 54: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

5. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 55: Transfer Case Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

6. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.

Front Wheel Drive Intermediate Shaft Bearing Removal

Special Tools

DT-307-B Remover Plate

For equivalent regional tools, refer to Special Tools.

 Fig. 56: Identifying Intermediate Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

1. Remove the transfer case intermediate shaft bearing retaining ring (2) from intermediate shaft (1), using
suitable pliers.
 Fig. 57: View Of Transfer Case Intermediate Shaft Bearing Removal
Courtesy of GENERAL MOTORS COMPANY

2. Remove the transfer case intermediate shaft bearing (1), using the DT-307-B remover plate and a
hydraulic press.
 Fig. 58: Intermediate Shaft O-Ring (Second Design)
Courtesy of GENERAL MOTORS COMPANY

3. Remove the intermediate shaft O-ring (3), as required.

Rear Output Shaft Seal Removal

 Fig. 59: View Of Rear Output Shaft Seal Sleeve
Courtesy of GENERAL MOTORS COMPANY

NOTE: Be sure to only pry against the five flat bosses on the rear output shaft
housing.

1. Remove the inner metal sleeve (1) from the seal by working a screwdriver around the perimeter of the
sleeve, prying only against the flat bosses of the output shaft housing.
 Fig. 60: View Of Rear Output Shaft Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE:  Be sure to only pry against the five flat bosses on the rear output
shaft housing.
 The seal tension spring (2) may fall off as the seal is removed.

2. Remove the rear output shaft seal (1) by working a sharpened chisel around the perimeter of the seal,
prying only against the flat bosses of the output shaft housing.
3. Ensure the seal tension spring (2) is removed from the bore.

Rear Output Shaft Housing Removal

 Fig. 61: Output Shaft Housing And Output Shaft Housing Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE:  Do not attempt to remove the rear output shaft housing (1) or bolts
(2) from the transfer case assembly.
 The rear output shaft, shaft bearings, housing (1) and housing O-ring
seal are not serviceable components.

1.

The rear output shaft seal (3) is a serviceable component. Refer to Rear Output Shaft Seal Removal and Rear
Output Shaft Seal Installation.

Rear Extension Housing Removal

 Fig. 62: Locating Transfer Case Rear Extension Housing Bolts
Courtesy of GENERAL MOTORS COMPANY

1. Remove the transfer case rear extension housing bolts (1) from the rear extension housing (2).
 Fig. 63: View Of Transfer Case Housing & Rear Extension Housing
Courtesy of GENERAL MOTORS COMPANY

2. Remove the rear extension housing (2) and bolts (3).

 Fig. 64: Rear Extension Housing-To-Transfer Case Seal
Courtesy of GENERAL MOTORS COMPANY

3. Remove and discard the rear extension housing-to-transfer case seal (1).

Input Shaft and Idler Shaft Removal

 Fig. 65: Identifying Idler Gear Shaft, Input Shaft & Idler Gear
Courtesy of GENERAL MOTORS COMPANY

1. Remove the input shaft (3)

2. Remove the idler gear (2).
3. Remove the idler gear shaft (1) - Model Dependent.

Input Shaft Bearing Retainer Front Seals Removal

 Fig. 66: Transfer Case Input Shaft Rear Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: There are two input shaft front seals located in the transfer case housing.

1. Remove the transfer case input shaft front (inner) seal (1) using a suitable screw driver.
 Fig. 67: Identifying Input Shaft Front Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: There are two input shaft front seals located in the transfer case housing.

2. Remove the transfer case input shaft front (outer) seal (1) using a suitable screw driver.

Idler Gear Shaft Front Seal Removal

Fig. 68: Transfer Case Idler Gear Shaft Front Seal
Courtesy of GENERAL MOTORS COMPANY

Remove the transfer case idler gear shaft front seal (1) from transfer case - Model Dependent.

Idler Gear Shaft Rear Seal Removal

Fig. 69: Identifying Idler Gear Shaft Rear Seal
Courtesy of GENERAL MOTORS COMPANY

Remove the transfer case idler gear shaft rear seal (1) from the rear extension housing - Model Dependent.

Input Shaft Bearing Retainer Rear Seal Removal

Fig. 70: Identifying Transfer Case Input Shaft Rear Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: To avoid damage to the housing, use a brass punch to remove the seal.

Remove the transfer case input shaft rear seal (1) from the rear extension housing.

Front Wheel Drive Intermediate Shaft Seal Removal

Fig. 71: Identifying Front Wheel Drive Intermediate Shaft Seal
Courtesy of GENERAL MOTORS COMPANY

Remove the intermediate shaft seal (1) from the rear extension housing using a suitable screw driver.

TRANSFER CASE CLEANING AND INSPECTION

Transfer Case Housing

 Fig. 72: Transfer Case Housing Components
Courtesy of GENERAL MOTORS COMPANY

NOTE: The bearings, shafts, gears, and housings are not serviceable
components. If damage to any of those components is present, the
transfer case must be replaced as an assembly.

1. Clean the front case half in cleaning solvent and air dry.
2. Inspect the housing for the following:
 Damage to threaded bolt holes (1 and 2)

 Damaged sealing surfaces (3)

 Bearing races (5) with wear or pitting

 Porosity

 External Damage

Rear Extension Housing

 Fig. 73: Rear Extension Housing Components
Courtesy of GENERAL MOTORS COMPANY

NOTE: The bearings, shafts, gears, and housings are not serviceable
components. If damage to any of those components is present, the
transfer case must be replaced as an assembly

1. Clean the rear case half in cleaning solvent and air dry.

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing
surface is a machined surface. Damage to the machined surface can
cause leakage. 2. Inspect the housing for the following:

2. Inspect the housing for the following:

 Damages sealing surfaces (1)

 Damage to threaded bolt holes (2)

 Bearing races (3) with wear or pitting

 Porosity

 External Damage
Input Shaft

Fig. 74: Input Shaft Inspection Points

Courtesy of GENERAL MOTORS COMPANY

NOTE: The bearings, shafts, gears, and housings are not serviceable
components. If damage to any of those components is present, the
transfer case must be replaced as an assembly

1. Clean the input shaft in cleaning solvent.

2. Inspect the input shaft splines (1) for excessive wear or damage.
3. Inspect the input shaft seal surfaces (2 and 5) for excessive grooves, rust, pitting or other damage.
4. Inspect the input shaft gear teeth (4) for excessive wear or damage.

Idler Gear and Idler Shaft

 Fig. 75: Idler Gear and Idler Shaft Inspection Areas
Courtesy of GENERAL MOTORS COMPANY

NOTE: The bearings, shafts, gears, and housings are not serviceable
components. If damage to any of those components is present, the
transfer case must be replaced as an assembly

1. Clean the idler shaft in cleaning solvent.

2. Inspect the idler shaft seal surfaces (8) for excessive grooves, rust, pitting or other damage. - Model
Dependent
3. Inspect the sealing surfaces of the idler gear shaft (5) for excessive grooves, rust, pitting or other damage.
- Model Dependent
4. Inspect the idler shaft gear teeth (3 and 4) for excessive wear or damage
5. Inspect the bearings (2 and 6) for pitting, wear or other damage.

TRANSFER CASE ASSEMBLE

Front Wheel Drive Intermediate Shaft Seal Installation

Special Tools
  DT-305-1/KM-305-1 Remover/Installer
 DT-49953 Seal Installer

For equivalent regional tools, refer to Special Tools.

Fig. 76: Intermediate Shaft Seal Installer

Courtesy of GENERAL MOTORS COMPANY

Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 installer (2) with DT-
305-1/KM-305-1 remover/installer (1) .

Input Shaft Bearing Retainer Rear Seal Installation

Special Tools

 DT-305-1/KM-305-1 Remover/Installer
 DT-49951 Seal Installer

For equivalent regional tools, refer to Special Tools

1. Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to
clean the threads of old threadlocking material.
 2. Spray thread cleaner into the holes. Refer to Adhesives, Fluids, Lubricants, and Sealers.

WARNING: Wear safety glasses when using compressed air in order to prevent
eye injury.

3. Clean the transfer case housing and rear extension housing bolt holes with compressed air.

Fig. 77: Installilng Input Shaft Bearing Retainer Rear Seal

Courtesy of GENERAL MOTORS COMPANY

NOTE: Install the NEW seal with the notched surface of the seal facing away from
the installer tool.

4. Install the NEW input shaft rear seal (1) to the rear extension housing using the DT-49951 installer (2)
and DT-305-1/KM-305-1 remover/installer (3).

Idler Gear Shaft Rear Seal Installation

Fig. 78: Identifying Idler Gear Shaft Rear Seal
Courtesy of GENERAL MOTORS COMPANY

Install a NEW idler gear shaft rear seal (1) to the rear extension housing - Model Dependent.

Idler Gear Shaft Front Seal Installation

Fig. 79: Transfer Case Idler Gear Shaft Front Seal
Courtesy of GENERAL MOTORS COMPANY

Install a NEW transfer case idler gear shaft front seal (1) to transfer case - Model Dependent.

Input Shaft Bearing Retainer Front Seals Installation

Special Tools

 DT-305-1/KM-305-1 Remover/Installer
 DT-49952 Installer

For equivalent regional tools, refer to Special Tools.

 Fig. 80: Identifying Input Shaft Bearing Retainer Front Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: Install the NEW seal with the notched surface of the seal facing the
installer tool.

1. Install the input shaft front (inner) seal (1), to the transfer case using the DT-49952 installer (2) and DT-
305-1/KM-305-1 remover/installer (3) .
 Fig. 81: Installing Input Shaft Front Seal
Courtesy of GENERAL MOTORS COMPANY

NOTE: Install the NEW seal with the notched surface of the seal facing the
installer tool.

2. Install the input shaft front (outer) seal (1), to the transfer case using the DT-49952 installer (2) and DT-
305-1/KM-305-1 remover/installer (3) .

Input Shaft and Idler Gear Installation

Fig. 82: Input Shaft And Idler Gear
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Cover the splines of the input shaft to prevent damage to the input shaft
oil seals during installation.

Install input shaft (1) and idler gear (2).

Rear Extension Housing Installation - Model Dependent

Fig. 83: Idler Gear Shaft
Courtesy of GENERAL MOTORS COMPANY

1. Install the idler gear shaft (1) to the rear extension housing - Model Dependent.
 Fig. 84: Rear Extension Housing-To-Transfer Case Seal
Courtesy of GENERAL MOTORS COMPANY

2. Install a NEW rear extension housing-to-transfer case seal (1).

 Fig. 85: Transfer Case Rear Extension Housing
Courtesy of GENERAL MOTORS COMPANY

3. Install the rear extension housing (1) and idler gear shaft to the transfer case housing. Position the idler
gear shaft into the center opening of the idler gear.
 Fig. 86: Locating Transfer Case Rear Extension Housing Bolts
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

4. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (1). Refer to
Adhesives, Fluids, Lubricants, and Sealers.
5. Install the NEW transfer case-to-rear extension housing bolts (1).
1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 N.m (18 lb ft).
2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.

Rear Extension Housing Installation - RPO MH4

Fig. 87: View Of Rear Extension Housing-To-Transfer Case Seal
Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW rear extension housing-to-transfer case seal (1).

2. Install the rear extension housing onto the transfer case housing .
 Fig. 88: Locating Transfer Case Rear Extension Housing Bolts
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

3. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts. Refer to
Adhesives, Fluids, Lubricants, and Sealers.
4. Install the NEW transfer case-to-rear extension housing bolts (1).
1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 N.m (18 lb ft).
2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 130 degrees.

Rear Output Shaft Seal Installation

Special Tools

 DT-305-1/KM-305-1 Remover/Installer
 DT-49954-A Seal Installer

For equivalent regional special tools, refer to Special Tools.

Fig. 89: View Of Rear Output Shaft Seal
Courtesy of GENERAL MOTORS COMPANY

Install the rear output shaft seal (3), using the DT-49954-A installer (2) and DT-305-1/KM-305-1
remover/installer (1).

Front Wheel Drive Intermediate Shaft Bearing Installation

Special Tools

DT-48076 Bearing Installer

For equivalent regional tools, refer to Special Tools.

 Fig. 90: View Of Intermediate Shaft Bearing And Bearing Installer
Courtesy of GENERAL MOTORS COMPANY

1. Press on the intermediate shaft bearing (2) onto the intermediate shaft (3), using DT-48076 installer (1)
and a hydraulic press.
 Fig. 91: Identifying Intermediate Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

2. Install the transfer case intermediate shaft bearing retaining ring (2) to intermediate shaft (1), using
suitable pliers.
 Fig. 92: Intermediate Shaft O-Ring (Second Design)
Courtesy of GENERAL MOTORS COMPANY

3. Install intermediate shaft O-ring (3), as required.

Front Wheel Drive Intermediate Shaft Installation

Special Tools

 DT-113-2-A Holder
 DT-622-A Transmission Bracket
 DT-48076 Bearing Installer
 DT-49104 Protective Collar

For equivalent regional tools, refer to Special Tools.

 Fig. 93: View Of Installing Intermediate Shaft
Courtesy of GENERAL MOTORS COMPANY

1. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft
using the DT-48076 installer (3) and a rubber mallet.
2. Remove the DT-49104 protective collar (1).
 Fig. 94: Intermediate Shaft Output Splines
Courtesy of GENERAL MOTORS COMPANY

3. Apply grease to the output splines (1) of the intermediate shaft. Refer to Adhesives, Fluids, Lubricants,
and Sealers.
 Fig. 95: Intermediate Shaft Retaining Ring
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

4. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
 Fig. 96: Shaft Dirt Deflector And Grease Seal
Courtesy of GENERAL MOTORS COMPANY

5. Install the dirt deflector (1) using the DT-48076 installer.

 Fig. 97: Seal And Special Installer Tool
Courtesy of GENERAL MOTORS COMPANY

6. Install the front wheel drive intermediate shaft dirt deflector (1) - model dependant using the DT 50768
seal installer (2) and J 8092 driver handle (3).

Locating Bushing Installation

Fig. 98: View Of Transfer Case Location Bushing
Courtesy of GENERAL MOTORS COMPANY

Install the transfer case locating bushing (1) as required using a rubber mallet - Model Dependent.

Transfer Case-to-Transmission Seal Installation

Fig. 99: Identifying Transfer Case-To-Transmission O-Ring
Courtesy of GENERAL MOTORS COMPANY

Install the NEW transfer case-to-transmission seal (1).

Transfer Case Vent Installation

 Fig. 100: View Of Transfer Case Vent
Courtesy of GENERAL MOTORS COMPANY

1. Apply sealant to the threads of the vent hose connector. Refer to Adhesives, Fluids, Lubricants, and
Sealers.
2. Install the transfer case vent hose connector (1) and tighten to 25 N.m (18 lb ft).

Oil Drain Plug Installation

Fig. 101: View Of Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

Install a NEW oil drain plug (1) and tighten to 40 N.m (30 lb ft).

Oil Fill Plug Installation

 Fig. 102: Identifying Transfer Case Fill Plug
Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW transfer case oil fill plug (1).

2. Once the transfer case has been filled with oil, tighten the oil fill plug to 40 N.m (30 lb ft).
 Fig. 103: Transmission Bracket, Transfer Case And Holder
Courtesy of GENERAL MOTORS COMPANY

3. Remove the transfer case (3) from DT-622-A bracket (2) and DT-113-2-A holder (1) .

DESCRIPTION AND OPERATION

TRANSFER CASE IDENTIFICATION

AAM First Design Label Location

Fig. 104: AAM First Design Label Location
Courtesy of GENERAL MOTORS COMPANY

The transfer case identification label (1) is located on the top of the front case half.

AAM First Design Label

Bar Code

Fig. 105: Bar Code Information Identification

Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

 1 GM Assigned Component Identification
2 Last 4 digits of GM Part Number
3 Supplier Identification
4 Calendar Year Produced
5 Julian Date
6 Supplier Serial Number
7 GM Part Number

AAM Second Design Label Location

Fig. 106: AAM Second Design Label Location

Courtesy of GENERAL MOTORS COMPANY

The transfer case identification label (1) is located on the side of the front case half.

AAM Second Design Label

Bar Code
Fig. 107: Bar Code Information Identification
Courtesy of GENERAL MOTORS COMPANY

Callout Component Name

1 GM Full Part Number
2 Broadcast Code
3 Supplier DUNs
4 VPPS Code
5 Supplier Trace Code

TRANSFER CASE DESCRIPTION AND OPERATION

Transfer Case Identification

Fig. 108: Locating Transfer Case Assembly Part Number
Courtesy of GENERAL MOTORS COMPANY

The build variation of transfer case can be identified by the assembly part number (1) located on the bottom of
the transfer case.

General
Fig. 109: Identifying Transfer Case Oil Drain Plug
Courtesy of GENERAL MOTORS COMPANY

The transfer case oil drain plug (1) is located at the bottom of the assembly to the right side of the rear output
shaft.
Fig. 110: View Of Transfer Case
Courtesy of GENERAL MOTORS COMPANY

The transfer case (1) is positioned in the right side of the vehicle and bolted to the transmission. Its primary
function is to receive power from the transmission and transfer it using helical and hypoid gear sets to the rear
differential via the propeller shaft. The internal intermediate shaft transfers power to the right-side front wheel.
Fig. 111: Cutaway View Of Transfer Case
Courtesy of GENERAL MOTORS COMPANY

The transfer case (1) is fully mechanical with no internal or external electronic controls or sensors.
Fig. 112: Identifying Fill Plug
Courtesy of GENERAL MOTORS COMPANY

During assembly the transfer case (1) is filled with oil, which then does not require service interval replacement.
The correct type of oil must be used when filling. The incorrect type of oil could lead to transfer case damage.
Refer to Adhesives, Fluids, Lubricants, and Sealers.

Housing and Cover

Fig. 113: View Of Transfer Case Housing & Rear Extension Housing
Courtesy of GENERAL MOTORS COMPANY

The transfer case housing (1) and rear extension housing (2) are produced from a high-pressure cast aluminium
alloy. A number of reinforcement ribs are fitted in suitable locations to strengthen the transfer case assembly.
These reinforcement ribs constitute a vital part of the cooling for the transfer case. The transfer case rear
extension housing is retained to the transfer case housing with bolts (3). Two dowel pins locate the extension
housing to the transfer case housing. The mating surfaces of transfer case housing and rear extension housing
are sealed by a press-in-place serviceable seal.
Fig. 114: Transfer Case Locating Bushing
Courtesy of GENERAL MOTORS COMPANY

The transfer case assembly is bolted to the transmission with four or five transfer case bolts. The sealing area
between the transfer case housing and the transmission is sealed with serviceable O-ring (1). Two opposite
radial seals seal the input shaft and prevent transmission and transfer case oil from mixing. If an input shaft seal
failure occurs, the transmission and transfer case fluids will not mix as there is a weep hole in the transfer case
housing between the two radial seals.
Fig. 115: Identifying Transfer Case Vent & Drain Plug
Courtesy of GENERAL MOTORS COMPANY

A transfer case vent (1) is located on the top area of the transfer case housing. The vent is mated to a remote
vent hose assembly that is routed into the engine compartment. The oil drain plug (2) is magnetic. A mounting
bracket retains the output end of the rear extension housing to the engine assembly.

Bearings and Races

Fig. 116: Transfer Case Bearings
Courtesy of GENERAL MOTORS COMPANY

There are tapered bearing races (1) in the transfer case housing and rear extension housing (2) for the input shaft
and idler shaft. Gear tooth clearances and bearing preloads are maintained by shims located behind the bearing
races. There is a sealed ball bearing type intermediate shaft bearing (3) located in the rear extension housing.
For some models, the transfer case rear extension housing has an opening (4) through which one of the
transmission-to-transfer case attaching bolts in accessed.

Input Shaft
Fig. 117: View Of Input Shaft & Components
Courtesy of GENERAL MOTORS COMPANY

The input shaft splines (6) are mated to and driven by the transmission differential housing. The rotational speed
of the input shaft is the same as the transmission output. Installed into the transfer case housing are two
opposing input shaft front seals (1). The two input shaft front seals are designed to restrict transmission oil from
entering the transfer case as well as restrict transfer case oil from entering the transmission. The opposite or rear
end of the input shaft is sealed by a double-lip intermediate shaft seal (5). The intermediate shaft seal (5) is
installed into the output end of the rear extension housing and is designed to restrict oil, dirt, and debris from
entering the transfer case. The helical gear teeth of the input shaft (3) are engaged to the helical gear teeth of the
idler shaft. The input shaft is mounted in two tapered roller bearings (2,4). The bearings are given the correct
preload during assembly by means of shims being fitted behind the bearing races in the housing and cover.

Idler Gear
Fig. 118: View Of Idler Shaft
Courtesy of GENERAL MOTORS COMPANY

The idler gear consists of a helical gear (3) and a hypoid gear (4), has a hollow center, and is driven by the
helical gear on the input shaft.

The idler hypoid gear (4) mates to and drives the hypoid gear on the rear output shaft. The input shaft, idler
gear, and rear output shaft gear sets are precision machined and are not serviceable.

The idler gear is mounted in two tapered roller bearings (2 and 5). The bearings are given the correct preload
and gears proper clearance during assembly by means of shims being fitted behind the bearing races in the
housing and cover. If the shims are removed for any reason, the shims need to be reinstalled to their original
locations.

For some models, there is an additional idler gear shaft (6) located inside and running through the idler gear.
The idler shaft is sealed at each end by O-ring seals (1 and 7) within the transfer case and rear extension
housings.

Rear Output Shaft Housing

Fig. 119: Exploded View Of Rear Output Shaft Housing
Courtesy of GENERAL MOTORS COMPANY

The rear output shaft housing assembly includes an output shaft (10), 2 tapered roller bearings (3 and 9), a rear
output shaft seal (1), shaft retaining nut (2), housing (7) and housing seal (12).

The hypoid gear of the rear output shaft is mated to the hypoid gear of the idler shaft. A shim (11) maintains the
proper gear contact.

The housing is retained to the transfer case by 7 bolts (6). The only serviceable component within the rear
output shaft and housing assembly is the rear output shaft seal (1).
Fig. 120: View Of Rear Output Shaft Seal
Courtesy of GENERAL MOTORS COMPANY

The only serviceable component within the rear output shaft and housing assembly is the rear output shaft seal
(3).

The seal is a unitized/cassette type design to include inner and outer metal sleeves and internal sealing rings.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

Tool
Number/
Illustration Description
 GE 8092
6-9606332
M-840911-A
J-8092
Driver
Handle
 DT-50768
Seal Installer
DT-113-2-A
J-03289-20
KM-113-2
Bracket
DT-305-1
J-42176
KM-305-1
Driver
Handle
DT-307 B
J-22912-B
KM-307-B
Remover
Plate
 DT-622-A
J-36842
KM-622-A
Transmission
Bracket
DT-48076
Bearing
Installer
DT-49104
Protective
Collar
 DT-49951
Seal Installer
 DT-49952
Seal Installer
 DT-49953
Seal Installer
DT-49954-A
Seal Installer