Home ReviewsRefund
Home/Buick/Encore/Buick Encore I (2012-2016)/Repair manual/Transfer Case - Aam/Front Wheel Drive Intermediate Shaft Replacement
Contents Wiring diagrams Section: Transfer Case - Aam All sections

Front Wheel Drive Intermediate Shaft Replacement Buick Encore I

Transfer Case - Aam 28 illustrations ~1335 words

Front Wheel Drive Intermediate Shaft Replacement

Special Tools

  1. J-41819 Input Shaft Seal Installer
  2. DT-50937 Seal Protector

For equivalent regional tools, refer to Special Tools .

  1. Remove the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side»(/buick/encore/i-2012-2016/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  2. Remove the front wheel drive intermediate shaft housing fasteners (1).
  3. Remove the front wheel drive intermediate shaft assembly (1).
  4. Inspect the bearing (1) and shaft (2) for wear or damage, if replacement is necessary, refer to Front Wheel Drive Intermediate shaft component disassembly in «Transfer Case Disassemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) , and «Transfer Case Assemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) for assembly.
  5. Remove and DISCARD the front wheel drive intermediate shaft seal (1).
  1. Using J-41819 Input Shaft Seal Installer install the NEW front wheel drive intermediate shaft seal (1).
  2. Using DT-50937 Seal Protector install the front wheel drive intermediate shaft assembly (1).
  3. Install the front wheel drive intermediate shaft housing fasteners (1) and tighten to 58 (43 lb ft).
  4. Install the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side»(/buick/encore/i-2012-2016/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/encore/i-2012-2016/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  3. Remove the rear propeller shaft. Refer to «Two-Piece Propeller Shaft Replacement»(/buick/encore/i-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  4. Remove the rear output shaft housing. Refer to Transfer Case Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  5. Remove the transfer case rear output shaft flange. Refer to Transfer Case Propeller Shaft Flange Removal in «Transfer Case Disassemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  6. Remove the transfer case rear output shaft seal. Refer to Transfer Case Rear Output Shaft Removal in «Transfer Case Disassemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Install the transfer case rear output shaft seal. Refer to Transfer Case Rear Output Shaft Installation in «Transfer Case Assemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Install the transfer case propeller shaft flange. Refer to Transfer Case Propeller Shaft Flange in «Transfer Case Assemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  3. Install the rear output shaft housing. Refer to Transfer Case Rear Output Shaft Housing Installation in «Transfer Case Assemble»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  4. Install the rear propeller shaft. Refer to «Two-Piece Propeller Shaft Replacement»(/buick/encore/i-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  5. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  6. Lower the vehicle.
  1. Disconnect the transfer case vent hose (1) from the transfer case.
  2. Drain the fluid from the transmission. Refer to «Transmission Fluid Drain and Fill»(/buick/encore/i-2012-2016/remont/automatic-trans/#automatic-transmission-6t40mh8-mhb-repair-instructions-on-vehicle) .
  3. Remove the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side»(/buick/encore/i-2012-2016/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  4. Remove the intermediate drive shaft from the transfer case. Refer to «Front Wheel Drive Intermediate Shaft Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__front-wheel-drive-intermediate-shaft-replacement) .
  5. Remove the front exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV)»(/buick/encore/i-2012-2016/remont/exhaust/#engine-exhaust-system) , «Exhaust Front Pipe Replacement»(/buick/encore/i-2012-2016/remont/exhaust/#engine-exhaust-system) .
  6. Remove the propeller shaft. Refer to «Two-Piece Propeller Shaft Replacement»(/buick/encore/i-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  7. Support the transfer case (2) with a suitable jack, and secure with suitable straps.
  8. Remove and DISCARD the four transfer case fasteners (1).
  9. Separate the transfer case (2) from the transmission and remove the transfer case.
  10. Remove and discard the transfer case-to-transfer case bracket seal (1).
  1. Clean the contact surfaces between the transfer case and the transfer case bracket.
  2. Install a new transfer case-to-transfer case bracket seal (1).
  3. Support the transfer case with a suitable jack, and secure with suitable straps.
  4. Raise and align the transfer case in the correct position in relation to the transmission.
  5. Install the transfer case (2) to the transfer case bracket.
  6. Install the NEW transfer case-to-transfer case bracket fasteners (1) and tighten to 100 (74 lb ft) plus 30-45 degrees.
  7. Install the intermediate drive shaft into the transfer case. Refer to «Front Wheel Drive Intermediate Shaft Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__front-wheel-drive-intermediate-shaft-replacement) .
  8. Install the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side»(/buick/encore/i-2012-2016/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement) .
  9. Install the propeller shaft. Refer to «Two-Piece Propeller Shaft Replacement»(/buick/encore/i-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  10. Connect the transfer case vent hose (1) to the transfer case.
  11. Install the front exhaust pipe. Refer to «Exhaust Front Pipe Replacement (LUV)»(/buick/encore/i-2012-2016/remont/exhaust/#engine-exhaust-system) , «Exhaust Front Pipe Replacement»(/buick/encore/i-2012-2016/remont/exhaust/#engine-exhaust-system) .
  12. Fill the transmission with fluid. Refer to «Transmission Fluid Drain and Fill»(/buick/encore/i-2012-2016/remont/automatic-trans/#automatic-transmission-6t40mh8-mhb-repair-instructions-on-vehicle) .
  13. Check the transfer case fluid. Refer to «Approximate Fluid Capacities»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__approximate-fluid-capacities) .
  1. Remove the transfer case. Refer to «Transfer Case Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Remove and DISCARD the transfer case adapter seal from the transmission adapter.
  3. Remove and DISCARD the five transmission adapter fasteners (1).
  4. Remove and DISCARD the rear transmission mount through bolt (1).
  5. Remove the transmission adapter (2) from the transmission.
  1. Install the transmission adapter (2) to the transmission.
  2. For manual transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
  3. For automatic transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
  4. Install the NEW transmission adapter to transmission fastener (2) and tighten to 60 N.m (44 lb ft) plus 60-75 degrees.
  5. Install the NEW rear transmission mount through bolt (1) and tighten to 80 N.m (59 lb ft) plus 45-60 degrees.
  6. Install the NEW transfer case adapter seal from the transmission adapter.
  7. Install the transfer case. Refer to «Transfer Case Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Remove the transfer case. Refer to «Transfer Case Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Remove and DISCARD the transfer case adapter seal from the transmission adapter.
  3. Remove and DISCARD the five transmission adapter fasteners (1).
  4. Remove and DISCARD the rear transmission mount through bolt (1).
  5. Remove the transmission adapter (2) from the transmission.
  6. Inspect the rear mount bushing the transmission adapter for wear or damage. Refer to «Transfer Case Adapter Disassemble (MHB)»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) , «Transfer Case Adapter Disassemble (M7Y, MZ4)»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Install the rear mount bushing to the transmission adapter. Refer to «Transfer Case Adapter Assemble (MHB)»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) , «Transfer Case Adapter Assemble (M7Y, MZ4)»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Install the transmission adapter (2) to the transmission.
  3. For manual transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
  4. For automatic transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
  5. Install the NEW transmission adapter to transmission fastener (2) and tighten to 60 N.m (44 lb ft) plus 60-75 degrees.
  6. Install the NEW rear transmission mount through bolt (1) and tighten to 80 N.m (59 lb ft) plus 45-60 degrees.
  7. Install the NEW transfer case adapter seal from the transmission adapter.
  8. Install the transfer case. Refer to «Transfer Case Replacement»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam) .

Scheme 2

Scheme 2: Transfer Case Adapter Disassemble (MHB)
Scheme 2: Transfer Case Adapter Disassemble (MHB)
CalloutComponent Name
1Transfer Case Adapter
2Transfer Case Adapter Seal
3Transfer Case Adapter Bushing Procedure Install the DT 50839 onto the adapter and over the bushing. Install the CH 50342 threaded rod through the bushing and DT 50839. Install the CH 50342 washers, nuts, and bearing onto the rod. Install the bearing onto the rod at the end closest to the DT 50839. Tighten the nuts until snug. Hold the flat on the threaded rod and rotate the top nut to remove the bushing from the bore of the adapter. Special Tools DT 50839 Transmission Adapter Plate Bushing Replacer CH 50342 Hardware Kit For equivalent regional tools, refer to Special Tools .

Transfer Case Adapter Disassemble (MHB)

Scheme 3

Scheme 3: Transfer Case Adapter Disassemble (M7Y, MZ4)
Scheme 3: Transfer Case Adapter Disassemble (M7Y, MZ4)
CalloutComponent Name
1Transfer Case Adapter
2Transfer Case Adapter Seal
3Transfer Case Adapter Bushing Procedure Install the DT 50839 onto the adapter and over the bushing. Install the CH 50342 threaded rod through the bushing and DT 50839. Install the CH 50342 washers, nuts, and bearing onto the rod. Install the bearing onto the rod at the end closest to the DT 50839. Tighten the nuts until snug. Hold the flat on the threaded rod and rotate the top nut to remove the bushing from the bore of the adapter. Special Tools DT 50839 Transmission Adapter Plate Bushing Replacer CH 50342 Hardware Kit For equivalent regional tools, refer to Special Tools .

Transfer Case Adapter Disassemble (M7Y, MZ4)

Scheme 4

Scheme 4: Transfer Case Holding Fixture Installation
Scheme 4: Transfer Case Holding Fixture Installation
CalloutComponent Name
1Transfer Case NOTE: Always secure with the pivot pin after rotating. NOTE: The transfer case can be rotated 360 degrees to facilitate repair. Special Tools DT 3289-20 Holding Fixture DT 36842 Transaxle Holding Fixture For equivalent regional tools, refer to Special Tools .
NOTE
Always secure with the pivot pin after rotating.
NOTE
The transfer case can be rotated 360 degrees to facilitate repair.

Transfer Case Holding Fixture Installation

Scheme 5

Scheme 5: Transfer Case Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal
Scheme 5: Transfer Case Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal
CalloutComponent Name
1Transfer Case Oil Drain Plug NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
2Transfer Case Oil Drain Plug Seal NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
3Transfer Case Oil Fill Plug NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
4Transfer Case Oil Fill Plug Seal NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
5Transfer Case Vent Hose Connector NOTE: Remove the vent hose connector only if replacement is required.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
Remove the vent hose connector only if replacement is required.

Transfer Case Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal

Scheme 6

Scheme 6: Front Wheel Drive Intermediate Shaft Components Removal
Scheme 6: Front Wheel Drive Intermediate Shaft Components Removal
CalloutComponent Name
NOTE: The intermediate drive shaft is to be removed from the transfer case assembly prior to the transfer case assembly being removed from the vehicle. Prior to removal of the shaft from the assembly, seal protector DT-50937 must be installed to avoid front wheel drive intermediate shaft seal damage. Refer to Transfer Case Description and Operation - New Service Assembly for additional information.
1Front Wheel Drive Intermediate Shaft CV Joint Retaining Ring
2Front Wheel Drive Intermediate Shaft CV Joint Seal
3Front Wheel Drive Intermediate Shaft Assembly
4Front Wheel Drive Intermediate Shaft Bearing Seal NOTE: Use a press to remove the seal from the housing. Use care to prevent damage to the housing seal bore.
5Front Wheel Drive Intermediate Shaft Housing NOTE: Use a press to remove the bearing from the housing.
6Front Wheel Drive Intermediate Shaft Housing Seal
7Front Wheel Drive Intermediate Shaft Bearing Retaining Ring 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.
8Front Wheel Drive Intermediate Shaft Bearing NOTE: Use a press to remove the bearing from the shaft.
NOTE
The intermediate drive shaft is to be removed from the transfer case assembly prior to the transfer case assembly being removed from the vehicle. Prior to removal of the shaft from the assembly, seal protector DT-50937 must be installed to avoid front wheel drive intermediate shaft seal damage. Refer to Transfer Case Description and Operation - New Service Assembly for additional information.
NOTE
Use a press to remove the seal from the housing. Use care to prevent damage to the housing seal bore.
NOTE
Use a press to remove the bearing from the housing.
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.
NOTE
Use a press to remove the bearing from the shaft.

Front Wheel Drive Intermediate Shaft Components Removal

Scheme 7

Scheme 7: Transfer Case Rear Output Shaft Housing Removal
Scheme 7: Transfer Case Rear Output Shaft Housing Removal
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Bolt (Qty: 4)
2Transfer Case Rear Output Shaft Housing Assembly
3Transfer Case Rear Output Shaft Housing Shim
4Transfer Case Rear Output Shaft Housing O-Ring Seal

Transfer Case Rear Output Shaft Housing Removal

Scheme 8

Scheme 8: Transfer Case Propeller Shaft Flange Removal
Scheme 8: Transfer Case Propeller Shaft Flange Removal
CalloutComponent Name
1Transfer Case Propeller Shaft Flange Nut Special Tools J 08614-A Pinion Flange Holder and Remover J 44873-2 Shoulder Bolts For equivalent regional tools, refer to Special Tools .
2Transfer Case Propeller Shaft Flange Special Tools J 08614-A Pinion Flange Holder and Remover J 44873-2 Shoulder Bolts For equivalent regional tools, refer to Special Tools .

Transfer Case Propeller Shaft Flange Removal

Scheme 9

Scheme 9: Transfer Case Rear Output Shaft Removal
Scheme 9: Transfer Case Rear Output Shaft Removal
CalloutComponent Name
1Transfer Case Rear Output Shaft Assembly Procedure Use a press to remove the shaft and bearings from the housing. Press the shaft downward only until separated from the rear bearing. Once the shaft and bearing are separated, the shaft must be angled and removed by hand to avoid contact between the raised surface in the rear output shaft housing and the raised surface on the rear output shaft.
2Transfer Case Rear Output Shaft Bearing Spacer NOTE: Discard the rear output shaft bearing spacer.
3Transfer Case Rear Output Shaft Seal NOTE: Use a press to remove the seal and bearing from the housing.
4Transfer Case Rear Output Shaft Rear Bearing NOTE: Use a press to remove the bearing and seal from the housing.
NOTE
Discard the rear output shaft bearing spacer.
NOTE
Use a press to remove the seal and bearing from the housing.
NOTE
Use a press to remove the bearing and seal from the housing.

Transfer Case Rear Output Shaft Removal

Scheme 10

Scheme 10: Transfer Case Rear Extension Housing Removal
Scheme 10: Transfer Case Rear Extension Housing Removal
CalloutComponent Name
1Transfer Case Rear Extension Housing Bolt (Qty: 11) NOTE: Do not reuse the case half bolts. Install NEW rear extension housing bolts during assembly.
2Transfer Case Rear Extension Housing Assembly
3Transfer Case Rear Extension Housing O-Ring Seal
NOTE
Do not reuse the case half bolts. Install NEW rear extension housing bolts during assembly.

Transfer Case Rear Extension Housing Removal

Scheme 11

Scheme 11: Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal R
Scheme 11: Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal R
CalloutComponent Name
1Front Wheel Drive Intermediate Shaft Seal Special Tools J 29369 Output Shaft Bearing Remover J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools .
2Input Shaft Rear Bearing Race NOTE: The bearing races are not an interference fit to the housing bore.
3Input Shaft Rear Shim NOTE: Note the position of the shim for assembly.
4Transfer Case Input Shaft Bearing Retainer Rear Seal Special Tools J 26941 Bushing and Bearing Remover J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools .
5Idler Shaft Rear Bearing Race NOTE: The bearing races are not an interference fit to the housing bore.
6Idler Shaft Rear Shim NOTE: Note the position of the shim for assembly.
NOTE
The bearing races are not an interference fit to the housing bore.
NOTE
Note the position of the shim for assembly.
NOTE
The bearing races are not an interference fit to the housing bore.
NOTE
Note the position of the shim for assembly.

Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal Removal

Scheme 12

Scheme 12: Idler Shaft and Input Shaft Removal
Scheme 12: Idler Shaft and Input Shaft Removal
CalloutComponent Name
1Idler Shaft Assembly
2Input Shaft Assembly

Idler Shaft and Input Shaft Removal

Scheme 13

Scheme 13: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Removal
Scheme 13: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Removal
CalloutComponent Name
1Idler Shaft Bearing Race NOTE: The bearing race is not an interference fit to the housing bore.
2Idler Shaft Bearing Race Shim NOTE: Note the position of the shim for assembly.
3Input shaft bearing race NOTE: The bearing race is not an interference fit to the housing bore.
NOTE
The bearing race is not an interference fit to the housing bore.
NOTE
Note the position of the shim for assembly.
NOTE
The bearing race is not an interference fit to the housing bore.

Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Removal

Scheme 14

Scheme 14: Transfer Case Input Shaft Bearing Retainer Front Seal and Rear Extension Locating Pin Removal
Scheme 14: Transfer Case Input Shaft Bearing Retainer Front Seal and Rear Extension Locating Pin Removal
CalloutComponent Name
1Transfer Case Rear Extension Housing Locating Pin, as required (Qty: 2)
2Transfer Case Input Shaft Bearing Retainer Front Seal Special Tools J 26941 Bushing and Bearing Remover J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools .

Transfer Case Input Shaft Bearing Retainer Front Seal and Rear Extension Locating Pin Removal

Scheme 15

Scheme 15: Transfer Case Housing Cleaning and Inspection
Scheme 15: Transfer Case Housing Cleaning and Inspection
CalloutComponent Name
Preliminary Procedure Clean the transfer case housing in cleaning solvent and air dry. The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.
1Transfer Case Housing NOTE: Inspect for cracks, broken areas, porosity, or other damage. The transfer case assembly must be replaced if damage is found.
2Transfer Case Housing Threaded Bolt Holes NOTE: Repair any damaged threads.
3Transfer Case Housing Sealing Surfaces NOTE: Repair small scratches or nicks with a soft stone.
4Drain Plug Hole NOTE: Inspect for damage to the threads or sealing surface.
NOTE
Inspect for cracks, broken areas, porosity, or other damage. The transfer case assembly must be replaced if damage is found.
NOTE
Repair any damaged threads.
NOTE
Repair small scratches or nicks with a soft stone.
NOTE
Inspect for damage to the threads or sealing surface.

Transfer Case Cleaning and Inspection

Scheme 16

Scheme 16: Transfer Case Rear Extension Housing Cleaning and Inspection
Scheme 16: Transfer Case Rear Extension Housing Cleaning and Inspection
CalloutComponent Name
Preliminary Procedure Clean the transfer case housing in cleaning solvent and air dry. The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.
1Transfer Case Rear Extension Housing NOTE: Inspect for cracks, broken areas, porosity, or other damage. The transfer case assembly must be replaced if damage is found.
2Transfer Case Rear Extension Housing Sealing Surfaces NOTE: Repair small scratches or nicks with a soft stone.
3Fill Plug Hole NOTE: Inspect for damage to the threads or sealing surface.
NOTE
Inspect for cracks, broken areas, porosity, or other damage. The transfer case assembly must be replaced if damage is found.
NOTE
Repair small scratches or nicks with a soft stone.
NOTE
Inspect for damage to the threads or sealing surface.

Transfer Case Cleaning and Inspection

Scheme 17

Scheme 17: Input Shaft Cleaning and Inspection
Scheme 17: Input Shaft Cleaning and Inspection
CalloutComponent Name
Preliminary Procedure Clean the input shaft in cleaning solvent and air dry. The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.
1Input Shaft Splines NOTE: Inspect for excessive wear or damage.
2Input Shaft Front Seal Surface NOTE: Inspect for excessive grooves, rust, pitting, or damage.
3Input Shaft Gear Teeth NOTE: Inspect for excessive wear or damage.
4Input Shaft Bearing NOTE: Inspect for bearing wear or other damage
5Input Shaft Rear Seal Surface NOTE: Inspect for excessive grooves, rust, pitting, or damage.
NOTE
Inspect for excessive wear or damage.
NOTE
Inspect for excessive grooves, rust, pitting, or damage.
NOTE
Inspect for excessive wear or damage.
NOTE
Inspect for bearing wear or other damage
NOTE
Inspect for excessive grooves, rust, pitting, or damage.

Transfer Case Cleaning and Inspection

Scheme 18

Scheme 18: Idler Shaft Cleaning and Inspection
Scheme 18: Idler Shaft Cleaning and Inspection
CalloutComponent Name
Preliminary Procedure Clean the idler shaft in cleaning solvent and air dry. The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.
1Idler Shaft Bearing NOTE: Inspect for bearing wear or other damage
2Idler Shaft Gear Teeth NOTE: Inspect for excessive wear or damage.
3Idler Shaft Bearing NOTE: Inspect for bearing wear or other damage
NOTE
Inspect for bearing wear or other damage
NOTE
Inspect for excessive wear or damage.
NOTE
Inspect for bearing wear or other damage

Transfer Case Cleaning and Inspection

Scheme 19

Scheme 19: Transfer Case Rear Output Shaft Installation
Scheme 19: Transfer Case Rear Output Shaft Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Bearing Spacer NOTE: Install a NEW rear output shaft bearing spacer.
2Transfer Case Rear Output Shaft Assembly
3Transfer Case Rear Output Shaft Rear Bearing NOTE: Use a press to install the rear bearing.
4Transfer Case Rear Output Shaft Seal Special Tools DT-45756 Seal Installer For equivalent regional tools, refer to Special Tools .
NOTE
Install a NEW rear output shaft bearing spacer.
NOTE
Use a press to install the rear bearing.

Transfer Case Rear Output Shaft Installation

Scheme 20

Scheme 20: Transfer Case Propeller Shaft Flange Installation
Scheme 20: Transfer Case Propeller Shaft Flange Installation
CalloutComponent Name
1Transfer Case Propeller Shaft Flange Procedure Apply sealant to the ID splines of the flange. Refer to Adhesives, Fluids, Lubricants, and Sealers . NOTE: Use a press to install the propeller shaft flange.
NOTE
Use a press to install the propeller shaft flange.

Transfer Case Propeller Shaft Flange Installation

Scheme 21

Scheme 21: Transfer Case Rear Output Shaft Housing Installation
Scheme 21: Transfer Case Rear Output Shaft Housing Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Shim NOTE: Use care to ensure the shim does not contact the O-ring seal.
2Transfer Case Rear Output Shaft Housing O-ring Seal Procedure Lube the seal with transfer case fluid prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers .
3Transfer Case Rear Output Shaft Housing Assembly
4Transfer Case Rear Output Shaft Housing Bolt (Qty: 4) Procedure Apply threadlocker to the threads of the NEW bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers . NOTE: Do not reuse the rear output shaft housing bolts. Install NEW rear output shaft housing bolts during assembly. Tighten 40 (30 lb ft)
5Transfer Case Propeller Shaft Flange Nut Procedure Apply threadlocker to the threads of the nut. Refer to Adhesives, Fluids, Lubricants, and Sealers . NOTE: Do not reuse the propeller shaft flange nut. Install a NEW flange nut during assembly. Tighten Tighten the nut a first pass to 100 (74 lb ft). Remove the tools. Measure the rotating torque of the rear shaft and flange and reinstall the tools and tighten the nut as required to achieve the correct rotating torque of 1.5-2.9 (13-26 lb in). Special Tools DT-08614-A Pinion Flange Holder and Remover DT-44873-2 Shoulder Bolts For equivalent regional tools, refer to Special Tools .
NOTE
Use care to ensure the shim does not contact the O-ring seal.
NOTE
Do not reuse the rear output shaft housing bolts. Install NEW rear output shaft housing bolts during assembly.
NOTE
Do not reuse the propeller shaft flange nut. Install a NEW flange nut during assembly.

Transfer Case Rear Output Shaft Housing Installation

Scheme 22

Scheme 22: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation
Scheme 22: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation
CalloutComponent Name
1Idler Shaft Bearing Shim NOTE: Note the position of the shim for assembly.
2Idler Shaft Bearing Race NOTE: The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
3Input Shaft Bearing Race NOTE: The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
4Transfer Case Rear Extension Housing Locating Pins (Qty: 2). NOTE: Install the locating pins as required.
NOTE
Note the position of the shim for assembly.
NOTE
The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
NOTE
The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
NOTE
Install the locating pins as required.

Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation

Scheme 23

Scheme 23: Idler Shaft and Input Shaft Installation
Scheme 23: Idler Shaft and Input Shaft Installation
CalloutComponent Name
1Input Shaft Assembly
2Idler Shaft Assembly

Idler Shaft and Input Shaft Installation

Scheme 24

Scheme 24: Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal I
Scheme 24: Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal I
CalloutComponent Name
1Front Wheel Drive Intermediate Shaft Seal Procedure In order to retain the intermediate shaft seal to the DT-41819 Input Shaft Seal Installer , it may be necessary to apply a thin layer of transmission assembly grease DT-36850 Transjel Lubricant to the face of the tool. Install the intermediate shaft seal (1), to the rear extension housing using the DT-41819 installer . Clean any residual grease from the face of the seal. NOTE: Inspect the tool flange for scratches or scoring. If tool damage is present, seal lip damage may occur. Replace the tool as required. Special Tools DT-36850 Transjel Lubricant DT-41819 Input Shaft Seal Installer For equivalent regional tools, refer to Special Tools .
2Transfer Case Input Shaft Bearing Retainer Rear Seal NOTE: Inspect the tool flange for scratches or scoring. If tool damage is present, seal lip damage may occur. Replace the tool as required. Use the small end of the tool to install the seal. Install the NEW seal with the notched metal surface of the seal facing the installer tool. Special Tools DT-8092 Driver Handle DT-50840 Input Shaft Seal Installer For equivalent regional tools, refer to Special Tools .
NOTE
Inspect the tool flange for scratches or scoring. If tool damage is present, seal lip damage may occur. Replace the tool as required.
NOTE
Inspect the tool flange for scratches or scoring. If tool damage is present, seal lip damage may occur. Replace the tool as required. Use the small end of the tool to install the seal. Install the NEW seal with the notched metal surface of the seal facing the installer tool.

Transfer Case Input Shaft Bearing Retainer Rear Seal and Front Wheel Drive Intermediate Shaft Seal Installation

Scheme 25

Scheme 25: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation
Scheme 25: Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation
CalloutComponent Name
1Input Shaft Rear Shim NOTE: Note the position of shims for assembly.
2Input Shaft Rear Bearing Race NOTE: The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
3Idler Shaft Rear Shim NOTE: Note the position of shims for assembly.
4Idler Shaft Rear Bearing Race NOTE: The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
NOTE
Note the position of shims for assembly.
NOTE
The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.
NOTE
Note the position of shims for assembly.
NOTE
The bearing races are not an interference fit to the housing bore. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

Transfer Case Input Shaft Bearing Race and Idler Shaft Bearing Race Installation

Scheme 26

Scheme 26: Transfer Case Rear Extension Housing Installation
Scheme 26: Transfer Case Rear Extension Housing Installation
CalloutComponent Name
1Transfer Case Rear Extension Housing O-ring Seal NOTE: Do not reuse the O-ring seal. Install a NEW O-ring seal during assembly. Inspect the extension housing and main housing seal surfaces to ensure they are clean and free of damage prior to assembly.
2Transfer Case Rear Extension Housing Assembly
3Transfer Case Rear Extension Housing Bolt (Qty: 11) Procedure Apply threadlocker to the threads of the NEW bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers . NOTE: Do not reuse the case half bolts. Install NEW rear extension housing bolts during assembly. Tighten First pass to 28 (21 lb ft) in sequence Final pass 90 degrees in sequence
NOTE
Do not reuse the O-ring seal. Install a NEW O-ring seal during assembly. Inspect the extension housing and main housing seal surfaces to ensure they are clean and free of damage prior to assembly.
NOTE
Do not reuse the case half bolts. Install NEW rear extension housing bolts during assembly.

Transfer Case Rear Extension Housing Installation

Scheme 27

Scheme 27: Transfer Case Input Shaft Bearing Retainer Front Seal Installation
Scheme 27: Transfer Case Input Shaft Bearing Retainer Front Seal Installation
CalloutComponent Name
1Input Shaft Seal Protector CAUTION: When installing the input shaft seal into the main housing, use the seal protector to prevent input shaft seal damage. The seal protector is included as a part of the service seal parts kit.
2Transfer Case Input Shaft Bearing Retainer Front Seal Procedure Install the seal protector over the splines of the input shaft. Remove the seal protector after the input shaft seal is installed into the housing. NOTE: The seal protector is part of the service seal kit. Use the large end of the DT-50840 to install the seal. Install the NEW seal with the notched metal surface of the seal facing away from the installer tool and facing the inside of housing. Special Tools DT-8092 Driver Handle DT-50840 Input Shaft Seal Installer For equivalent regional tools, refer to Special Tools .
CAUTION
When installing the input shaft seal into the main housing, use the seal protector to prevent input shaft seal damage. The seal protector is included as a part of the service seal parts kit.
NOTE
The seal protector is part of the service seal kit. Use the large end of the DT-50840 to install the seal. Install the NEW seal with the notched metal surface of the seal facing away from the installer tool and facing the inside of housing.

Transfer Case Input Shaft Bearing Retainer Front Seal Installation

Scheme 28

Scheme 28: Front Wheel Drive Intermediate Shaft Components Installation
Scheme 28: Front Wheel Drive Intermediate Shaft Components Installation
CalloutComponent Name
Preliminary Procedure The intermediate drive shaft is to be installed into the transfer case assembly after the transfer case assembly is installed into the vehicle. Prior to installation of the shaft into the assembly, seal protector DT-50937 must be installed to avoid front wheel drive intermediate shaft seal damage. Refer to Transfer Case Description and Operation - New Service Assembly for additional information.
1Front Wheel Drive Intermediate Shaft Bearing NOTE: Use a press to install the bearing to the shaft. Special Tools DT-50985 Seal Installer For equivalent regional tools, refer to Special Tools .
2Front Wheel Drive Intermediate Shaft Bearing Retaining Ring 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.
3Front Wheel Drive Intermediate Shaft Housing NOTE: Use a press to install the housing to the bearing. Special Tools DT-50985 Seal Installer For equivalent regional tools, refer to Special Tools .
4Front Wheel Drive Intermediate Shaft Housing Seal
5Front Wheel Drive Intermediate Shaft Bearing Seal Special Tools DT-50985 Seal Installer For equivalent regional tools, refer to Special Tools .
6Front Wheel Drive Intermediate Shaft CV Joint Seal
7Front Wheel Drive Intermediate Shaft Retaining Ring CAUTION: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it. NOTE: Do not reuse the intermediate shaft retaining ring. Install a NEW ring during assembly.
NOTE
Use a press to install the bearing to the shaft.
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.
NOTE
Use a press to install the housing to the bearing.
CAUTION
When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.
NOTE
Do not reuse the intermediate shaft retaining ring. Install a NEW ring during assembly.

Front Wheel Drive Intermediate Shaft Components Installation

Scheme 29

Scheme 29: Transfer Case Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation
Scheme 29: Transfer Case Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation
CalloutComponent Name
1Transfer Case Oil Drain Plug Seal NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
2Transfer Case Oil Drain Plug NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly. Tighten 40 (30 lb ft)
3Transfer Case Oil Fill Plug Seal NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
4Transfer Case Oil Fill Plug Procedure Tighten the oil fill plug only after the assembly has been filled with fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers . NOTE: The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly. Tighten 40 (30 lb ft)
5Transfer Case Vent Hose Connector Procedure Apply sealant to the threads of the connector. Refer to Adhesives, Fluids, Lubricants, and Sealers . Tighten 25 (18 lb ft)
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
NOTE
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

Transfer Case Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation