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Transfer Case - Getrag 790 Buick Enclave I

Transfer Case 30 illustrations ~2877 words

Approximate Fluid Capacities

ApplicationSpecification
MetricEnglish
Synthetic Lubricant- Transfer Case1.0 liter1.06 quart

Approximate Fluid Capacities

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Transfer Case Drain Plug39 N.m29 lb ft
Transfer Case Fill Plug39 N.m29 lb ft
Transfer Case Half Bolts (Qty: 11)29 N.m21 lb ft
Transfer Case Rear Output Drive Gear Nut (Qty: 1)235 N.m173 lb ft
Transfer Case Rear Output Drive Shaft Housing Bolts (Qty: 6)29 N.m21 lb ft

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
Rear Output Shaft NutThreadlocker1234538210953489
Transfer Case FillSAE 75W-90 Synthetic8890040189021678

Adhesives, Fluids, Lubricants, and Sealers

Scheme 1

Scheme 1: Transfer Case Disassembled View
Scheme 1: Transfer Case Disassembled View
CalloutComponent Name
1Transfer Case Input Shaft Seal - Left
2Transfer Case O-ring Seal
3Transfer Case - Left
4Transfer Case Half Locating Pin (Qty: 2)
5Transfer Case Rear Output Drive Shaft
6Transfer Case Input Shaft
7Front Drive Axle Intermediate Shaft Seal Assembly
8Transfer Case Input Shaft Seal - Right
9Transfer Case Seal
10Transfer Case Vent Assembly
11Transfer Case - Right
12Transfer Case Fill Plug
13Transfer Case Drain Plug
14Transfer Case Half Bolt (Qty: 11)
15Half Shaft Retainer
16Front Wheel Drive Retainer
17O-ring
18Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
19Front Wheel Drive Intermediate Shaft Bearing Assembly
20Front Wheel Drive Intermediate Shaft
21Transfer Case Rear Output Shaft
22Transfer Case Rear Output Shaft Bearing Assembly (Qty: 2)
23Transfer Case Rear Output Shaft Bearing Spacer
24Transfer Case Rear Output Shaft Housing Seal O-ring
25Transfer Case Rear Output Shim
26Transfer Case Rear Output Shaft Housing
27Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
28Transfer Case Rear Output Shaft Seal
29Transfer Case Rear Output Shaft Oil Slinger
30Transfer Case Rear Output Shaft Flange
31Transfer Case Rear Output Shaft Nut

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 Rear Drive Axle 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

  1. Inspect for aftermarket devices, which could affect the operation of the vehicle. Refer to «Checking Aftermarket Accessories»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__checking-aftermarket-accessories) .
  2. Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom.
  3. Inspect for the correct lubricant levels and the proper viscosities.
  4. Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed, road conditions, ambient temperature, and other specifics.
  5. 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

  1. «Diagnostic System Check - Vehicle»(/buick/enclave/i-2007-2013/remont/oem-general-information/#vehicle-diagnostic-information)
  2. «Noisy in Drive»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__noisy-in-drive)
  3. «Noisy When Coasting»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__noisy-when-coasting)
  4. «Intermittent Noise»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__intermittent-noise)
  5. «Constant Noise»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__constant-noise)
  6. «Transfer Case Leak Diagnosis»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__transfer-case-leak-diagnosis)

Noisy in Drive

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Low gear oil levelInspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers .
Incorrect gear oil in the transfer caseReplace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Water or contamination within the lubricantReplace the lubricant and flush the transfer case of the contaminated fluid.
Loose propeller shaft mounting boltsInspect the bolts and replace and tighten as required. Refer to Propeller Shaft Replacement .
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Propeller Shaft Replacement .
Worn axle shaft constant velocity jointsReplace the constant velocity joints, as required.
Worn bearing in the driveline torque tube assemblyReplace the driveline torque tube assembly.
Loose driveline torque tube bracket or a worn bracket bushingTighten the bracket bolts or replace the driveline torque tube assembly as required.
Overheated rear drive axle clutch A chatter type noise during hard or heavy acceleration and/or low speed turns may be within the rear differential.Rear drive axle clutch overheated or axle low on fluid. Refer to Symptoms - Rear Differential Carrier .
Worn bearing in the differential assemblyRepair or replace the assembly.
Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a 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.Test drive the vehicle to verify the noise is transfer case or wheel bearing related. Duplicate the noise with the vehicle fully assembled and on a hoist. Using a stethoscope or CH-39570 chassis ears , determine if the source of the noise is within the transfer case. NOTE: The removal of the right side axle shaft will stop the front axle and both front wheels from spinning. Remove the right side axle shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement Run the vehicle on the hoist to confirm the noise is present. If the noise is present, it is transfer case related. Replace as Required If the noise is NOT present, the noise is wheel bearing related, repair as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission 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.Test drive the vehicle to verify the noise is transfer case or wheel bearing related. Duplicate the noise with the vehicle fully assembled and on a hoist. Using a stethoscope or CH-39570 chassis ears , determine if the source of the noise is within the transfer case. NOTE: The removal of the right side axle shaft will stop the front axle and both front wheels from spinning. Remove the right side axle shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement Run the vehicle on the hoist to confirm the noise is present. If the noise is present, it is transfer case related. Replace as Required If the noise is NOT present, the noise is wheel bearing related, repair as required.
NOTE
The removal of the right side axle shaft will stop the front axle and both front wheels from spinning.
NOTE
The removal of the right side axle shaft will stop the front axle and both front wheels from spinning.

Noisy in Drive

Noisy When Coasting

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Low gear oil levelInspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers .
Incorrect gear oil in the transfer caseReplace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Loose propeller shaft mounting boltsInspect the bolts and replace and tighten as required. Refer to Propeller Shaft Replacement .
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Propeller Shaft Replacement .
Worn axle shaft constant velocity jointsReplace the constant velocity joints, as required.
Loose driveline torque tube bracket or a worn bracket bushingTighten the bracket bolts or replace the driveline torque tube assembly as required.
Overheated rear drive axle clutch A chatter type noise during hard or heavy acceleration and/or low speed turns may be within the rear differential.Rear drive axle clutch overheated or axle low on fluid. Refer to Symptoms - Rear Differential Carrier .
Worn bearing in the differential assemblyRepair or replace the assembly as required.
Wheel bearing noise or bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a 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.Test drive the vehicle to verify the noise is transfer case or wheel bearing related. Duplicate the noise with the vehicle fully assembled and on a hoist. Using a stethoscope or CH-39570 chassis ears , determine if the source of the noise is within the transfer case. Remove the right side axle shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement TIP: The removal of the right side axle shaft will stop the front axle and both front wheels from spinning. Run the vehicle on the hoist to confirm the noise is present. If the noise is present, it is transfer case related. Replace as Required If the noise is NOT present, the noise is wheel bearing related, repair as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission 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.Test drive the vehicle to verify the noise is transfer case or wheel bearing related. Duplicate the noise with the vehicle fully assembled and on a hoist. Using a stethoscope or CH-39570 chassis ears , determine if the source of the noise is within the transfer case. Remove the right side axle shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement TIP: The removal of the right side axle shaft will stop the front axle and both front wheels from spinning. Run the vehicle on the hoist to confirm the noise is present. If the noise is present, it is transfer case related. Replace as Required If the noise is NOT present, the noise is wheel bearing related, repair as required.

Noisy When Coasting

Intermittent Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Incorrect gear oil in the transfer case case.Replace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Loose driveline torque tube bracket or a worn bracket bushingTighten the bracket bolts or replace the driveline torque tube assembly as required.
Overheated rear drive axle clutch A chatter type noise during hard or heavy acceleration and/or low speed turns may be within the rear differential.Rear drive axle clutch overheated or axle low on fluid. Refer to Symptoms - Rear Differential Carrier .
Loose propeller shaft mounting boltsInspect the bolts and replace and tighten as required. Refer to Propeller Shaft Replacement .
Transfer case, wheel bearing, or rear drive axle clutch module A chatter or ratcheting type noise during hard acceleration on tight turns.Confirm noise is coming from the transfer case or the rear drive axle clutch module. Repair as required Refer to Symptoms - Rear Differential Carrier . Test drive the vehicle to verify the noise is transfer case or wheel bearing related. Duplicate the noise with the vehicle fully assembled and on a hoist. Using a stethoscope or CH-39570 chassis ears , determine if the source of the noise is within the transfer case. Remove the right side axle shaft from the vehicle. Refer to Front Wheel Drive Shaft Replacement TIP: The removal of the right side axle shaft will stop the front axle and both front wheels from spinning. Run the vehicle on the hoist to confirm the noise is present. If the noise is present, it is transfer case related. Replace as Required If the noise is NOT present, the noise is wheel bearing related, repair as required.

Intermittent Noise

Constant Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Low gear oil levelInspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers .
Incorrect gear oil in the transfer caseReplace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Propeller Shaft Replacement .
Worn bearing in the differential assemblyRepair or replace the assembly as required.
Loose driveline torque tube bracket or a worn bracket bushingTighten the bracket bolts or replace the driveline torque tube assembly as required.
Overheated rear drive axle clutch A chatter type noise during hard or heavy acceleration and/or low speed turns may be within the rear differential.Rear drive axle clutch overheated or axle low on fluid. Refer to Symptoms - Rear Differential Carrier .
Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a 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.Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace components, as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case A whine noise that changes as a transmission 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.Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace components, as required.

Constant Noise

Transfer Case Leak Diagnosis

CauseCorrection
Drain and fill the unit with new oil with ultraviolet dye GE-28431-6 Fluorescent Oil Dye - 6 1-oz before using the GE-28428-E/J-4220 High-Intensity Black Light Kit , when inspecting for leaks.
Drain plug or fill plug leakInspect for worn, scored, or missing drain and/or fill plug sealing washers. Replace as required. Refer to Transfer Case Fluid Replacement .
Restricted or damaged ventilation assemblyReplace the ventilation assembly, as required.
Leaking at the transfer case left side weep hole A transmission oil leak at the transmission-to-transfer case interface or weep hole area may be caused by the transmission to transfer case O-ring seal or transmission right side drive shaft seal. A gear oil leak at the transmission-to-transfer case interface or weep hole area is caused by the transfer case input seal.Replace components as required.. Refer to Transfer Case Disassemble , and Transfer Case Assemble . If the leak is transmission or O-ring related, do not replace the transfer case input seal.
Leaking at the transfer case right side weep hole A transmission oil leak at the transfer case right side weep hole is caused by the intermediate drive shaft seal. A gear oil leak at the transfer case right side weep hole is caused by the right side input seal.Identify the type of oil leak. Replace components as required.
Leaking at rear output shaft area A leak at rear output shaft area is caused by either the rear output shaft seal or the rear output shaft housing O-ring seal.Inspect and replace the O-ring or rear output shaft seal as required.
Leaking at transaxle assembly-to-transfer case interface A transmission oil leak at the transmission-to-transfer case interface may be caused by the transmission to transfer case O-ring seal or the transmission right side drive shaft seal.NOTE: If the leak is transmission or O-ring related, do not replace the transfer case input seal. Identify the type of oil leak. Replace components as required.
Case half seam leakDisassemble and replace the transfer case seal. Refer to Transfer Case Disassemble , and Transfer Case Assemble .
Leaking through caseInspect for a cracked case. Inspect for case porosity. Replace the transfer case.
NOTE
If the leak is transmission or O-ring related, do not replace the transfer case input seal.

Transfer Case Leak Diagnosis

Removal Procedure

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the drain plug.
  3. Remove the fill plug.

Installation Procedure

  1. Clean the drain plug.
  2. Install the drain plug and tighten to 39 (29 lb ft).
  3. Fill the transfer case with lubricant to the bottom of the fill plug, or 1 Liter (34 oz). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__adhesives-fluids-lubricants-and-sealers) for lubricant recommendation.
  4. Clean the fill plug.
  5. Install the fill plug and tighten to 39 (29 lb ft).
  6. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the drain plug.
  3. Remove the fill plug.
  1. Clean the drain plug.
  2. Install the drain plug and tighten to 39 (29 lb ft).
  3. Fill the transfer case with lubricant to the bottom of the fill plug, or 1 Liter (34 oz). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790__adhesives-fluids-lubricants-and-sealers) for lubricant recommendation.
  4. Clean the fill plug.
  5. Install the fill plug and tighten to 39 (29 lb ft).
  6. Lower the vehicle.
  1. Remove the fill plug.
  1. Install the fill plug and tighten to 39 (29 lb ft).

Scheme 2

Scheme 2: Transfer Case Vent Hose Replacement
Scheme 2: Transfer Case Vent Hose Replacement
CalloutComponent Name
1Transfer Case Vent Hose
2Transfer Case Vent Nipple
3Hose Clamp
4Engine Assembly Procedure Disconnect electrical connectors as necessary. Transfer components as necessary.

Transfer Case Vent Hose Replacement

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the transfer case rear output shaft flange and seal. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  1. Install the transfer case rear output shaft seal. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  1. Install the transfer case rear output shaft flange and slinger. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  6. Remove the transfer case rear output shaft oil slinger from the transfer case rear output shaft flange.
  1. Install the transfer case rear output shaft flange and slinger. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the O-ring, half shaft retainer, intermediate shaft bearing retainer and bearing from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  1. Install the O-ring, half shaft retainer, intermediate shaft bearing retainer and bearing to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the intermediate shaft bearing retainers and bearing from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  1. Install the intermediate shaft bearing and retainers to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the half shaft retainer and O-ring seal from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  1. Install the O-ring seal and half shaft retainer to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Remove the transfer case rear output shaft housing seal O-ring.
  1. Install the transfer case rear output shaft housing seal O-ring.
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Drain the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(/buick/enclave/i-2007-2013/remont/automatic-trans/#automatic-transmission-6t75-repair-instructions-on-vehicle) .
  4. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  5. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(/buick/enclave/i-2007-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  6. Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(/buick/enclave/i-2007-2013/remont/exhaust/#engine-exhaust-system) .
  7. Support the transaxle with a jackstand.
  8. Remove the engine rear mount bracket. Refer to «Engine Rear Mount Bracket Replacement (Front Wheel Drive)»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) , «Engine Rear Mount Bracket Replacement (All Wheel Drive)»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
  9. Remove the transfer case bolts (1).
  10. Remove the transfer case (2).
  1. Lubricate the O-rings (2, 3) with automatic transmission fluid.
  2. Install the NEW transfer case O-ring seal (3).
  3. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
  4. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  5. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
  6. Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
  7. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
  8. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.
  9. Install the transfer case (1) to the transmission.
  10. Remove the guide pins (2).
  11. Install the transfer case to transmission bolts (1) and tighten to 50 N.m (37 lb ft).
  12. Install the engine rear mount bracket. Refer to «Engine Rear Mount Bracket Replacement (Front Wheel Drive)»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) , «Engine Rear Mount Bracket Replacement (All Wheel Drive)»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
  13. Remove the jackstand from under the transaxle.
  14. Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(/buick/enclave/i-2007-2013/remont/exhaust/#engine-exhaust-system) .
  15. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(/buick/enclave/i-2007-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  16. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  17. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  18. Fill the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(/buick/enclave/i-2007-2013/remont/automatic-trans/#automatic-transmission-6t75-repair-instructions-on-vehicle) .
  19. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/enclave/i-2007-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  3. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(/buick/enclave/i-2007-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  5. Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(/buick/enclave/i-2007-2013/remont/exhaust/#engine-exhaust-system) .
  6. Support the transaxle with a jackstand.
  7. Remove the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
  8. Remove the transfer case bolts (1).
  9. Remove the transfer case (2).
  1. Lubricate the O-rings (2, 3) with automatic transmission fluid.
  2. Install the NEW transfer case O-ring seal (3).
  3. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
  4. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  5. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
  6. Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
  7. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
  8. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.
  9. Install the transfer case (1) to the transmission.
  10. Remove the guide pins (2).
  11. Install the transfer case to transmission bolts (1) and tighten to 50 N.m (37 lb ft).
  12. Install the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(/buick/enclave/i-2007-2013/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
  13. Remove the jackstand from under the transaxle.
  14. Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(/buick/enclave/i-2007-2013/remont/exhaust/#engine-exhaust-system) .
  15. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(/buick/enclave/i-2007-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  16. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/enclave/i-2007-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  17. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/enclave/i-2007-2013/remont/transfer-case/#transfer-case-getrag-790) .
  18. Lower the vehicle.

Scheme 3

Scheme 3: Housing O-ring, Vent Assembly, Drain and Fill Plug Removal
Scheme 3: Housing O-ring, Vent Assembly, Drain and Fill Plug Removal
CalloutComponent Name
1Transfer Case O-ring Seal
2Transfer Case Vent Assembly TIP: Remove the vent only if damaged or blocked.
3Transfer Case Drain Plug
4Transfer Case Fill Plug

Housing O-ring, Vent Assembly, Drain and Fill Plug Removal

Scheme 4

Scheme 4: Intermediate Drive Shaft Removal
Scheme 4: Intermediate Drive Shaft Removal
CalloutComponent Name
1Front Wheel Drive Retainer
2Front Wheel Drive Intermediate Shaft

Intermediate Drive Shaft Removal

Scheme 5

Scheme 5: Rear Output Shaft Housing Removal
Scheme 5: Rear Output Shaft Housing Removal
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2Transfer Case Rear Output Shaft Housing TIP: Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal.
3Transfer Case Rear Output Shim
4Transfer Case Rear Output Shaft Housing Seal O-ring TIP: Discard the O-ring after removal.

Rear Output Shaft Housing Removal

Scheme 6

Scheme 6: Right Transfer Case, Input and Output Drive Shaft Removal
Scheme 6: Right Transfer Case, Input and Output Drive Shaft Removal
CalloutComponent Name
1Transfer Case Half Bolt (Qty: 11)
2Transfer Case - Right
3Transfer Case Seal from the Transfer Case - Right
4Transfer Case Input Shaft
5Transfer Case Rear Output Drive Shaft
6Transfer Case Half Locating Pin (Qty: 2) Remove the pins only if damaged. Inspect the case for similar damage. TIP: Refer to Transfer Case Cleaning and Inspection .

Right Transfer Case, Input and Output Drive Shaft Removal

Scheme 7

Scheme 7: Rear Output Shaft Housing Disassembly
Scheme 7: Rear Output Shaft Housing Disassembly
CalloutComponent Name
1Transfer Case Rear Output Shaft Gear Nut TIP: Use a 30 mm socket or J 29873 Nozzle Socket 30 mm. Special Tools J-08614-A Pinion Flange Holder and Remover J 29873 Nozzle Socket 30 mm For equivalent regional tools, refer to Special Tools .
2Transfer Case Rear Output Shaft Flange Special Tools DT-48145 Press Support For equivalent regional tools, refer to Special Tools .
3Transfer Case Rear Output Shaft Bearing Assembly TIP: Use a press to remove the output shaft from the housing.
4Transfer Case Rear Output Shaft Bearing Spacer
5Transfer Case Rear Output Shaft
6Transfer Case Rear Output Shaft Oil Slinger TIP: Remove the slinger only if damaged. Refer to Rear Output Drive Housing Cleaning and Inspection .
7Transfer Case Rear Output Shaft Seal TIP: Discard the seal after removal.

Rear Output Shaft Housing Disassembly

Scheme 8

Scheme 8: Intermediate Drive Shaft Disassembly
Scheme 8: Intermediate Drive Shaft Disassembly
CalloutComponent Name
1Half Shaft Retainer
2O-ring
3Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
4Front Wheel Drive Intermediate Shaft Bearing Assembly TIP: Use a press, with the J 22912-B Rear Pinion and Axle Bearing Remover flat side up, in order to remove the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools .

Intermediate Drive Shaft Disassembly

Scheme 9

Scheme 9: Transfer Case Cleaning and Inspection
Scheme 9: Transfer Case Cleaning and Inspection
CalloutComponent Name
CAUTION: Refer to Machined Surface Damage Caution . Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean the left and right transfer case in cleaning solvent and air dry.
1Transfer Case - Left and Right TIP: Inspect for cracks, broken areas, or other damage. The transfer case assembly must be replaced if damage is found.
2Transfer Case Rear Output Drive Housing Bore TIP: Repair small scratches or nicks with light sanding.
3Case Sealing Surface TIP: Repair small scratches or nicks with a soft stone.
4Transfer Case Bearing Races TIP: Replace the transfer case assembly if a bearing has spun or if cracks are detected.
5Transfer Case Thread Bolt Holes TIP: Repair any damaged threads.
6Transfer Case Half Locating Pin Holes
CAUTION
Refer to Machined Surface Damage Caution .

Transfer Case Cleaning and Inspection

Scheme 10

Scheme 10: Rear Output Drive Housing Cleaning and Inspection
Scheme 10: Rear Output Drive Housing Cleaning and Inspection
CalloutComponent Name
Preliminary Procedures Clean all components in cleaning solvent and air dry. The transfer case internal components are not to be serviced. If internal components other than seals are damaged, the transfer case must be replaced.
1Transfer Case Rear Output Shaft Flange Replace if flange, threaded holes, or splines are damaged. Inspect sealing surface for corrosion, excessive wear, or damage.
2Transfer Case Rear Output Shaft Oil Slinger TIP: Replace the slinger if damaged, cracked, loose, or distorted.
3Transfer Case Rear Output Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.
4Transfer Case Rear Output Shaft Housing Inspect for cracks, broken areas, or other damage. Inspect bearing races for roughness, brinelling, or pitting. Inspect the O-ring channel for porosity or damage. Scratches or nicks in other areas may be repaired with light sanding.
5Transfer Case Rear Output Shaft Splines TIP: Inspect for damage and press fit to flange.
6Transfer Case Rear Output Shaft TIP: Inspect for pitting, excessive wear, or damage.

Rear Output Drive Housing Cleaning and Inspection

Scheme 11

Scheme 11: Input Shaft Seal Replacement - Right
Scheme 11: Input Shaft Seal Replacement - Right
CalloutComponent Name
1Transfer Case Input Shaft Seal - Right CAUTION: Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. Special Tools DT-48074 Input and Output Shaft Seal Installer J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools .
CAUTION
Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface.

Input Shaft Seal Replacement - Right

Scheme 12

Scheme 12: Input Shaft Seal Replacement - Left
Scheme 12: Input Shaft Seal Replacement - Left
CalloutComponent Name
1Transfer Case Input Shaft Seal - Left CAUTION: Do not use a screwdriver or punch to remove or install the seal. Using a screwdriver or punch to remove or install the seal may damage the aluminum housing sealing surface. Procedure Lightly lubricate the outer diameter (OD) of the seal with clean gear lube prior to installation. To ensure proper alignment and depth of the seal, take four measurements every 90 degrees around the seal circumference, verifying uniform depth. The distance from the top face of the machined surface of the bore to the metal flange of the seal should be 24.3 ± 0.1 mm (0.957 ± 0.004 in). Failure to follow these instructions will result in replacement seal failure. TIP: Alignment of seal is critical and use of correct tool is necessary. The machined surface of the bore must be clean and free from scratches or nicks. Special Tools DT-48074 Input and Output Shaft Seal Installer J-8092 Driver Handle DT-26941/KM-J-26941 Bushing and Bearing Remover - 3-4 in DT-45124 Removal Bridge For equivalent regional tools, refer to Special Tools .
CAUTION
Do not use a screwdriver or punch to remove or install the seal. Using a screwdriver or punch to remove or install the seal may damage the aluminum housing sealing surface.

Input Shaft Seal Replacement - Left

Scheme 13

Scheme 13: Front Drive Axle Inner Shaft Seal Replacement
Scheme 13: Front Drive Axle Inner Shaft Seal Replacement
CalloutComponent Name
1Front Drive Axle Intermediate Shaft Seal Assembly TIP: DT-48078 seal installer seats the seal to a specific depth. Other installation methods may set the seal to a non-functional depth. Special Tools DT-48078 Inner Drive Shaft Seal Installer J 8092 Universal Driver For equivalent regional tools, refer to Special Tools .

Front Drive Axle Inner Shaft Seal Replacement

Scheme 14

Scheme 14: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
Scheme 14: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
CalloutComponent Name
Preliminary Procedures Clean all components in cleaning solvent and air dry. The transfer case internal components are not to be serviced. If internal components other than seals are damaged, the transfer case must be replaced.
1Transfer Case Input Shaft Gear TIP: Inspect for pitting, excessive wear, or damage.
2Transfer Case Rear Output Drive Shaft Gear TIP: Inspect for pitting, excessive wear, or damage.
3Transfer Case Input Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.
4Transfer Case Rear Output Drive Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.

Input Shaft and Rear Output Drive Shaft Cleaning and Inspection

Scheme 15

Scheme 15: Intermediate Drive Shaft Assembly
Scheme 15: Intermediate Drive Shaft Assembly
CalloutComponent Name
1Front Wheel Drive Intermediate Shaft
2Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
3Front Wheel Drive Intermediate Shaft Bearing Assembly TIP: Use a press, with the DT-22912-B/KM-307-B Rear Pinion and Axle Bearing Remover flat side up, in order to install the bearing assembly. Special Tools DT-22912-B/KM-307-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools .
4O-ring
5Half Shaft Retainer

Intermediate Drive Shaft Assembly

Scheme 16

Scheme 16: Rear Output Shaft Housing Assembly
Scheme 16: Rear Output Shaft Housing Assembly
CalloutComponent Name
1Transfer Case Rear Output Shaft
2Transfer Case Rear Output Shaft Bearing Spacer
3Transfer Case Rear Output Shaft Housing
4Transfer Case Rear Output Shaft Bearing Assembly TIP: Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the housing and bearings to the output shaft. Special Tools J-5590 Pinion Bearing Race Installer - Rear For equivalent regional tools, refer to Special Tools .
5Transfer Case Rear Output Shaft Seal TIP: Use a press with the DT-48075 Output Shaft Seal Installer to install the seal. Special Tools DT-48075 Output Shaft Seal Installer For equivalent regional tools, refer to Special Tools .

Rear Output Shaft Housing Assembly

Scheme 17

Scheme 17: Output Flange Installation
Scheme 17: Output Flange Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Oil Slinger TIP: Use a press with the DT-48077 Output Shaft Slinger Installer in order to install the slinger. Special Tools DT-48077 Output Shaft Slinger Installer For equivalent regional tools, refer to Special Tools .
2Transfer Case Rear Output Shaft Flange TIP: Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the flange. Special Tools J-5590 Pinion Bearing Race Installer - Rear For equivalent regional tools, refer to Special Tools .
3Transfer Case Rear Output Shaft Nut CAUTION: Refer to Fastener Caution . The rear output shaft nut is supplied with a dry retaining compound patch. If reusing the nut, apply GM P/N 12345382 (Canadian P/N 10953489) to the threads. Use the J-08614-A Pinion Flange Holder and Remover and a 30 mm socket or the EN-29873 Injector Nozzle Socket 30 mm. Tighten 235 N.m (173 lb ft) Special Tools J-08614-A Pinion Flange Holder and Remover EN-29873 Injector Nozzle Socket 30 mm For equivalent regional tools, refer to Special Tools .
CAUTION
Refer to Fastener Caution .

Output Flange Installation

Scheme 18

Scheme 18: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
Scheme 18: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
CalloutComponent Name
1Transfer Case Half Locating Pin (Qty: 2)
2Transfer Case Input Shaft TIP: Install the input and output shafts as a set with the splines engaged.
3Transfer Case Rear Output Drive Shaft
4Transfer Case Seal to the Transfer Case - Right
5Transfer Case - Right
6Transfer Case Half Bolt (Qty: 11) CAUTION: Refer to Fastener Caution Tighten 29 N.m (21 lb ft)
CAUTION
Refer to Fastener Caution

Right Transfer Case, Input Shaft, and Output Drive Shaft Installation

Scheme 19

Scheme 19: Rear Output Shaft Housing Installation
Scheme 19: Rear Output Shaft Housing Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Seal O-ring
2Transfer Case Rear Output Shim
3Transfer Case Rear Output Shaft Housing CAUTION: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth. Use of a heat gun allows easy alignment of the bolt holes to the housing during assembly. Rotate the pinion gear during assembly to engage the gear teeth. Special Tools EL-25070 Heat Gun - 500-750F For equivalent regional tools, refer to Special Tools .
4Transfer Case Rear Output Shaft Housing Bolt (Qty: 6) CAUTION: Refer to Fastener Caution Tighten 29 N.m (21 lb ft)
CAUTION
Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth.
CAUTION
Refer to Fastener Caution

Rear Output Shaft Housing Installation

Scheme 20

Scheme 20: Intermediate Drive Shaft Installation
Scheme 20: Intermediate Drive Shaft Installation
CalloutComponent Name
1Front Wheel Drive Intermediate Shaft CAUTION: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage. Special Tools DT-48094 Inner Drive Shaft Seal Protector For equivalent regional tools, refer to Special Tools .
2Front Wheel Drive Retainer
CAUTION
DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage.

Intermediate Drive Shaft Installation

Housing O-ring, Vent Assembly, Drain and Fill Plug Installation

CalloutComponent Name
1Transfer Case O-ring Seal
2Transfer Case Vent Assembly TIP: Replace the vent if damaged or blocked.
3Drain Plug CAUTION: Refer to Fastener Caution Tighten 39 N.m (29 lb ft)
4Fill Plug Tighten 39 N.m (29 lb ft)
CAUTION
Refer to Fastener Caution

Housing O-ring, Vent Assembly, Drain and Fill Plug Installation

Scheme 21

Scheme 21: Transfer Case Description and Operation
Scheme 21: Transfer Case Description and Operation

The transfer case in this vehicle consists of an aluminum housing with input helical gear, output driven helical gear, ring and pinion hypoid gear set, and an intermediate drive shaft.

The transfer case transfers torque/power to the on-demand rear differential through a propshaft assembly.

The on-demand rear differential distributes variable torque/power to the rear wheels through individual axle shafts.

Within the rear differential assembly is an active on-demand coupling system.

The on-demand system rear differential control module monitors wheel speed, vehicle speed, wheel slippage, and other variables. The module directs the rear differential to distribute torque to the rear wheels as required.

Typical conditions when torque is applied are during vehicle launches, even without wheel slip, and when there is front wheel slippage relative to the rear wheels. The amount of torque depends on the vehicle speed and the amount of wheel slippage.

New Product Information

The purpose of New Product Information is to document, important product changes which occur either model year-to-model year or interim model year.

Changes may include one or more of the following items

  1. Specification changes
  2. New sealants and/or adhesives
  3. Disassembly and assembly procedure revisions
  4. Mechanical and diagnostic procedure revisions
  5. New special tools required
  6. Interim model year design changes
  7. A component comparison from the previous model year

Scheme 22

Scheme 22: Identification Tag Marking
Scheme 22: Identification Tag Marking
CalloutComponent Name
1GM Part Number
2Getrag Serial Number

Special Tools

Illustration Tool Number/Description DT-48074 Input and Output Shaft Seal Installer DT-48075 Output Shaft Seal Installer DT-48077 Output Shaft Slinger Installer DT-48078 Inner Drive Shaft Seal Installer DT-48094 Inner Drive Shaft Seal Protector DT-48145 Press Support J 5590 Pinion Bearing Race Installer - Rear J 8092 Driver Handle J-08614-A Pinion Flange Holder and Remover DT-22912-B J 22912-B KM-307-B Rear Pinion and Axle Bearing Remover EL-25070 J 25070 Heat Gun - 500-750F DT 26941 J 26941 KM-J 26941 Bushing and Bearing Remover - 3-4 in GE 28431-6 J 28431-6 Flourescent Oil Dye-6 1-oz GE 28428-E J 4220 J 28428-E High-Intensity Black Light Kit EN 29873 J 29873 Injector Nozzle Socket 30 mm CH 39570 J 39570 Chassis Ears DT 45124 J 45124 Removal Bridge

Scheme 23

Scheme 23: Special Tools
Scheme 23: Special Tools

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30