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Transfer Case - Aam Buick Encore I

Transfer Case 51 illustrations ~2711 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Front Wheel Drive Intermediate Shaft Housing Bolts58 N.m43 lb ft
Transfer Case Adapter Plate-to-Transmission Bolts (1) (for Automatic Transmission)
First pass100 N.m74 lb ft
Second pass30-40 degrees
Transfer Case Adapter Plate-to-Transmission Bolts (2) (for Automatic Transmission)
First pass60 N.m44 lb ft
Second pass60-75 degrees
Transfer Case-to-Adapter Plate Bolts
First pass100 N.m74 lb ft
Second pass30-40 degrees
Transfer Case Adapter Plate-to-Transmission Bolts (1) (for Manual Transmission)
First pass100 N.m74 lb ft
Second pass30-40 degrees
Oil Fill Plug40 N.m30 lb ft
Oil Drain Plug40 N.m30 lb ft
Rear Extension Housing-to-Main Housing Bolts
First pass28 N.m21 lb ft
Second pass90 degrees
Rear Output Shaft Housing-to-Main Housing Bolts40 N.m30 lb ft
Rear Output Flange Nut - Minimum torque - Tighten additional as required to obtain the correct rotating torque100 N.m74 lb ft
Rear Output Flange - Rotating Torque1.5-2.9 N.m13-26 lb in
Vent Hose Connector25 N.m18 lb ft

Fastener Tightening Specifications

Approximate Fluid Capacities

ApplicationSpecification
MetricEnglish
Transfer Case Oil0.35 liters0.36 quarts

Approximate Fluid Capacities

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
Transfer Case OilLubricant1925608419256085
Intermediate Shaft Output SplinesLubricant105134400993037
Rear Extension Housing-to-Main Housing BoltsThreadlocker8902129710953488
Rear Extension Housing Bolt HolesCleaner8886265088901247
Rear Output Shaft Housing-to-Main Housing BoltsThreadlocker8902129710953488
Rear Output Flange NutThreadlocker8902129710953488
Rear Output Shaft Splines and Rear Output Flange SplinesSealant1234600410953480
Vent Hose Connector ThreadsSealant1234600410953480

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 Bearing Retainer Front Seal
2Transfer Case Rear Output Shaft Housing Locating Pin
3Transfer Case Housing
4Transfer Case Rear Extension Housing O-Ring Seal
5Idler Shaft Front Bearing Shim
6Idler Shaft Front Bearing Race
7Idler Shaft Front Bearing
8Idler Shaft
9Idler Shaft Rear Bearing
10Idler Shaft Rear Bearing Race
11Idler Shaft Rear Bearing Shim
12Input Shaft
13Input Shaft Front Bearing
14Input Shaft Front Bearing Race
15Input Shaft Rear Bearing
16Input Shaft Rear Bearing Race
17Input Shaft Rear Bearing Shim
18Transfer Case Input Shaft Bearing Retainer Rear Seal
19Transfer Case Rear Extension Housing Locating Pin
20Transfer Case Rear Extension Housing Bolt
21Transfer Case Rear Extension Housing
22Front Wheel Drive Intermediate Shaft Seal
23Transfer Case Oil Fill Plug
24Transfer Case Oil Fill Plug Seal
25Front Wheel Drive Intermediate Shaft
26Front Wheel Drive Intermediate Shaft Bearing
27Front Wheel Drive Intermediate Shaft Bearing Retaining Ring
28Front Wheel Drive Intermediate Shaft Housing Seal
29Front Wheel Drive Intermediate Shaft Housing
30Front Wheel Drive Intermediate Shaft Bearing Seal
31Front Wheel Drive Intermediate Shaft CV Joint Seal
32Front Wheel Drive Intermediate Shaft Retaining Ring
33Transfer Case Propeller Shaft Flange Nut
34Transfer Case Propeller Shaft Flange
35Transfer Case Rear Output Shaft Seal
36Transfer Case Rear Output Shaft Rear Bearing
37Transfer Case Rear Output Shaft Bearing Spacer
38Transfer Case Rear Output Shaft Rear Bearing Race
39Transfer Case Rear Output Shaft Housing
40Transfer Case Rear Output Shaft Housing Shim
41Transfer Case Rear Output Shaft Housing O-Ring Seal
42Transfer Case Rear Output Shaft Housing Bolt
43Transfer Case Vent Hose Connector
44Transfer Case Vent Hose
45Transfer Case Vent Hose Clip
46Transfer Case Oil Drain Plug
47Transfer Case Oil Drain Plug Seal
48Transfer Case Rear Output Shaft Front Bearing Race
49Transfer Case Rear Output Shaft Front Bearing
50Transfer Case Rear Output Shaft
51Transfer Case Adapter
52Transfer Case Adapter Bushing
53Transmission-to-Transfer Case Adapter Seal

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/encore/i-2012-2016/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/encore/i-2012-2016/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) .
  2. «Noisy in Drive»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__noisy-in-drive) .
  3. «Noisy When Coasting»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__noisy-when-coasting) .
  4. «Intermittent Noise»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__intermittent-noise) .
  5. «Constant Noise»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__constant-noise) .
  6. «Transfer Case Leak Diagnosis»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__transfer-case-leak-diagnosis) .

Noisy in Drive

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
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 transfer case oilReplace the transfer case oil and flush the transfer case of the contaminated fluid.
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Symptoms - Propeller Shaft .
Worn or noisy wheel bearingsReplace the wheel bearings as required. Refer to Wheel Bearings Diagnosis .
Worn wheel drive shaft constant velocity jointsReplace the constant velocity joints, as required. Refer to Symptoms - Wheel Drive Shafts .
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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly 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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly as required.

Noisy in Drive

Noisy When Coasting

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
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 Symptoms - Propeller Shaft .
Worn wheel drive shaft constant velocity jointsReplace the constant velocity joints, as required. Refer to Symptoms - Wheel Drive Shafts .
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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly 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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly as required.

Noisy When Coasting

Intermittent Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Incorrect gear oil in the transfer caseReplace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Transfer case bearing. A chatter or ratcheting type noise during hard acceleration on tight turns.Confirm noise is coming from the transfer case. Repair as required.

Intermittent Noise

Constant Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
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 Symptoms - Propeller Shaft .
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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly 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 transfer case fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, inspect the internal components. If damage is present, replace the assembly as required.

Constant Noise

Transfer Case Leak Diagnosis

CauseCorrection
DEFINITION: A visible indication of an external fluid leak from the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections. See below for suggested diagnostic method(s).
Special Tools GE 28431-6 Fluorescent Oil Dye GE 28428-E High Intensity Black Light Kit For equivalent regional tools, refer to Special Tools . Fluorescent Dye Method Add GE 28431-6 Fluorescent dye to the transmission or transfer case to determine the source of the leak. Operate the vehicle. Inspect for the presence of dye within the oil leak using the GE 28428-E High Intensity Black Light Kit. A presence or non-presence of dye within the oil leak will indicate which component is the source of the leak. Powder Method CAUTION: Do not clean using brake cleaner or other reactive solvents as these solvents can damage rubber gaskets, seals and bushings. Thoroughly clean the suspected leak area using a rag. Apply an aerosol type leak tracing powder to the suspected leak area. NOTE: Do not drive the vehicle on the freeway as this will splatter oil inhibiting leak diagnosis. Operate the vehicle for 15-20 minutes under city driving conditions until normal operating temperatures are reached. Shut OFF the engine. Inspect the suspected leak area. Trace the leak path through the powder in order to find the source of the leak.
Drain plug or fill plug leakInspect for dirty, worn, scored sealing surfaces, or missing drain and/or fill plug sealing washers. Replace as required.
Restricted or damaged ventilation hose assemblyReplace the ventilation hose assembly, as required.
Leaking ATF at the transaxle -to-transfer case interfaceNOTE: An ATF leak at the transaxle-to-transfer case interface may be caused by the transfer case adapter seal or a damaged sealing surface. If the leak is transmission or O-ring related, do not replace the transfer case input shaft bearing retainer front seal. Identify the location of the leak and type of fluid. Replace the transfer case adapter seal as required. Refer to Transfer Case Replacement .
Leaking at the transfer case vent hole - main housingNOTE: An ATF leak at the transaxle-to-transfer case interface may be caused by the transfer case adapter seal or a damaged sealing surface. If the leak is transmission or O-ring related, do not replace the transfer case input shaft bearing retainer front seal. An automatic transmission fluid (ATF) or transfer case gear oil leak at the transfer case vent hole is caused by the transfer case input shaft bearing retainer front seal.Replace components as required.Refer to Transfer Case Description and Operation , and Transfer Case Replacement .
Leaking at the transfer case vent hole - extension housingNOTE: An automatic transmission fluid (ATF) or transfer case gear oil leak at the extension housing vent hole is caused by the input shaft bearing retainer seal located in the rear extension housing. Replace the transfer case input shaft bearing retainer rear seal.Refer to Transfer Case Description and Operation , and Transfer Case Replacement .
Leaking ATF at the intermediate shaft bearing locationNOTE: The front wheel drive intermediate shaft bearing seal is a dirt and debris seal only and not a fluid retaining seal and is not the source of a fluid leak. Inspect the front wheel drive intermediate shaft (IDS) bearing for excessive wear. A worn IDS shaft bearing may cause excessive shaft runout and seal leakage. Replace the front wheel drive intermediate shaft bearing as required. Replace the front wheel drive intermediate shaft seal and the front wheel drive intermediate shaft housing seal. Refer to Transfer Case Disassembled View , and Transfer Case Description and Operation .
Leaking at rear output shaft areaNOTE: A transfer case gear oil leak at rear output shaft area may be caused by either the rear output shaft seal, the rear output flange with damage to the seal surface, or a leaking rear output shaft housing O-ring seal. Replace the components as required.Refer to Transfer Case Description and Operation .
Case half seam leak AAMDisassemble and replace the transfer case-to-rear extension housing O-ring seal.
Leaking through the caseInspect for a cracked case. Inspect for case porosity. Replace the components as required.
CAUTION
Do not clean using brake cleaner or other reactive solvents as these solvents can damage rubber gaskets, seals and bushings.
NOTE
Do not drive the vehicle on the freeway as this will splatter oil inhibiting leak diagnosis.
NOTE
An ATF leak at the transaxle-to-transfer case interface may be caused by the transfer case adapter seal or a damaged sealing surface. If the leak is transmission or O-ring related, do not replace the transfer case input shaft bearing retainer front seal.
NOTE
An ATF leak at the transaxle-to-transfer case interface may be caused by the transfer case adapter seal or a damaged sealing surface. If the leak is transmission or O-ring related, do not replace the transfer case input shaft bearing retainer front seal.
NOTE
An automatic transmission fluid (ATF) or transfer case gear oil leak at the extension housing vent hole is caused by the input shaft bearing retainer seal located in the rear extension housing.
NOTE
The front wheel drive intermediate shaft bearing seal is a dirt and debris seal only and not a fluid retaining seal and is not the source of a fluid leak.
NOTE
A transfer case gear oil leak at rear output shaft area may be caused by either the rear output shaft seal, the rear output flange with damage to the seal surface, or a leaking rear output shaft housing O-ring seal.

Transfer Case Leak Diagnosis

Removal Procedure

  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. Place a suitable drain pan under the transfer case.
  3. Remove the drain plug (2) and discard.
  4. Remove the fill plug (1) and discard.

Installation Procedure

  1. Install the new drain plug.
  2. Tighten the drain plug to 40 (30 lb ft).
  3. Fill the transfer case to the bottom of the fill plug hole. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/encore/i-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers)
  4. Install a NEW fill plug and tighten to 40 (30 lb ft).
  5. Lower the vehicle.
  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. Remove the drain plug (2) and discard.
  3. Remove the fill plug (1) and discard.
  1. Install the new drain plug.
  2. Tighten the drain plug to 40 (30 lb ft).
  3. Fill the transfer case to the bottom of the fill plug hole.
  4. Install a NEW fill plug and tighten to 40 (30 lb ft).
  5. Lower the vehicle.
  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. Remove the fill plug (1) and discard.
  1. Install a NEW fill plug.
  2. Tighten the fill plug to 40 (30 lb ft).
  3. Lower the vehicle.
  1. Unclip the upper portion of the vent hose (2) from the retaining clip (1).
  2. Raise the vehicle on a hoist. Refer to «Lifting and Jacking the Vehicle»(/buick/encore/i-2012-2016/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  3. Disconnect the vent hose (1) from the transfer case (2).
  4. Remove the vent hose from the vehicle.
  1. Connect the vent hose (1) to the transfer case (2).
  2. Lower the vehicle.
  3. Clip the upper portion of the vent hose (2) to the retaining clip (1).

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

Transfer Case Holding Fixture Removal

CalloutComponent Name
1Transfer Case Special Tools DT-3289-20 Holding Fixture DT-36842 Transaxle Holding Fixture For equivalent regional tools, refer to Special Tools .

Transfer Case Holding Fixture Removal

Scheme 30

Scheme 30: Transfer Case Adapter Assemble (MHB)
Scheme 30: Transfer Case Adapter Assemble (MHB)
CalloutComponent Name
1Transfer Case Adapter Bushing Procedure Position the bushing (1) to the bore of the adapter plate. Align the opening of the bushing to the alignment mark on the face of the adapter. Mark the side of the bushing for alignment. Install the DT 50839 onto the adapter. Install the CH-50342 threaded rod through the bushing and the 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 bushing. Tighten the nuts until snug. Hold the flat on the threaded rod and rotate the bottom nut in order to install the bushing into the bore of the adapter. Tighten until the bushing has contacted the face of the installer tool. Inspect the bushing for proper installation. A properly installed bushing will be centered in the bore with 1.5-2.5 mm (0.06-0.10 in) of the bushing protruding from each side of the plate. Special Tools DT 50839 Transmission Adapter Plate Bushing Replacer CH-50342 Hardware Kit For equivalent regional tools, refer to Special Tools .
2Transfer Case Adapter-to-Transfer Case Seal NOTE: Install the OD groove of the seal onto the raised area in the adapter seal bore. A properly installed seal will be installed 2.66 mm (0.10 in) below the machined surface when measured from the bushing alignment mark side of the adapter.
3Transfer Case Adapter
NOTE
Install the OD groove of the seal onto the raised area in the adapter seal bore. A properly installed seal will be installed 2.66 mm (0.10 in) below the machined surface when measured from the bushing alignment mark side of the adapter.

Transfer Case Adapter Assemble (MHB)

Scheme 31

Scheme 31: Transfer Case Adapter Assemble (M7Y, MZ4)
Scheme 31: Transfer Case Adapter Assemble (M7Y, MZ4)
CalloutComponent Name
1Transfer Case Adapter Bushing Procedure Position the bushing (1) to the bore of the adapter plate. Align the opening of the bushing to the alignment mark on the face of the adapter. Mark the side of the bushing for alignment. Install the DT 50839 onto the adapter. Install the CH-50342 threaded rod through the bushing and the 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 bushing. Tighten the nuts until snug. Hold the flat on the threaded rod and rotate the bottom nut in order to install the bushing into the bore of the adapter. Tighten until the bushing has contacted the face of the installer tool. Inspect the bushing for proper installation. A properly installed bushing will be centered in the bore with 1.5-2.5 mm (0.06-0.10 in) of the bushing protruding from each side of the plate. Special Tools DT 50839 Transmission Adapter Plate Bushing Replacer CH-50342 Hardware Kit For equivalent regional tools, refer to Special Tools .
2Transfer Case Adapter-to-Transfer Case Seal NOTE: Install the seal into the bore until the face of the seal contacts the flange in the adapter seal bore.
3Transfer Case Adapter
NOTE
Install the seal into the bore until the face of the seal contacts the flange in the adapter seal bore.

Transfer Case Adapter Assemble (M7Y, MZ4)

Scheme 32

Scheme 32: Transfer Case Identification
Scheme 32: Transfer Case Identification

The transfer case primary identification label (1) is located on the rear extension housing. The transfer case secondary identification stamping (2) is located on the bottom of the main housing.

Scheme 33

Scheme 33: Transfer Case Primary Identification Label
Scheme 33: Transfer Case Primary Identification Label
  1. GM Part Number
  2. Broadcast Code
  3. Supplier Manufacturing Location
  4. VPPS
  5. Broadcast Code / Trace Code

Scheme 34

Scheme 34: Transfer Case Secondary Identification Stamping
Scheme 34: Transfer Case Secondary Identification Stamping
  1. GM Part Number
  2. Build Hour
  3. Daily Build Count
  4. Day of the Year
  5. Model Year
  6. BOM Code

Scheme 35

Scheme 35: General Description
Scheme 35: General Description

The transfer case is positioned in the right side of the vehicle and bolted to the transmission via an adapter plate. The primary function of the transfer case is to receive power from the transmission and transfer it using helical and hypoid gear sets through the propeller shaft to the rear differential. The transfer case housing, rear extension shaft housing, and rear output shaft housing are cast aluminum design.

Scheme 36

Scheme 36: External Components
Scheme 36: External Components
  1. Rear Output Flange
  2. Vent House Assembly
  3. Intermediate Drive Shaft - Right Axle Shaft
  4. Oil Fill Plug
  5. Oil Drain Plug
  6. Intermediate Drive Shaft - Transmission Input
  7. Input Shaft - Transmission Input
  8. Vent Hole - Front wheel drive input shaft bearing retainer front seal
  9. Vent Hole - Front wheel drive input shaft bearing retainer rear seal

Scheme 37

Scheme 37: Internal Components
Scheme 37: Internal Components

The OD splines of the input shaft (7) are mated to the ID splines of the transmission output shaft. Power and torque are transferred from the input shaft (7) to the idler shaft (4) via a helical gear set. A second gear set, the hypoid gear set (3) transfers power and torque from the idler shaft to the rear output shaft and flange (1). The propeller shaft is mated to the rear output shaft flange providing power and torque to the rear drive axle. The OD splines of the intermediate drive shaft (6) mate to the ID splines of the transmission carrier assembly and provide power and torque to the right front axle shaft and wheel.

Gear tooth clearances and bearing preloads are maintained by shims located behind the bearing races. The housings, internal gears, and bearings are not serviceable components. If housing, gear set, or bearing damage occurs, the assembly must be replaced.

  1. Rear Output Flange
  2. Rear Output Shaft Seal
  3. Rear Output Shaft
  4. Idler Shaft
  5. Front Wheel Drive Input Shaft Bearing Retainer Front Seal
  6. Intermediate Drive Shaft-to-Transmission Splines
  7. Input Shaft
  8. Front Wheel Drive Input Shaft Bearing Retainer Rear Seal
  9. Intermediate Drive Shaft
  10. Front Wheel Drive Intermediate Drive Shaft Bearing Seal
  11. Front Wheel Drive Intermediate Drive Shaft Seal

Scheme 38

Scheme 38: Transfer Case Service Assembly
Scheme 38: Transfer Case Service Assembly

New transfer case assemblies are shipped with the intermediate drive shaft (IDS) assembly (2) partially installed and retained to the transfer case assembly by a shipping clip (1). The shipping clip is to be removed and discarded. Prior to removal or installation of the IDS shaft, seal protector DT-50937 (3) must be installed to avoid front wheel drive intermediate shaft seal damage.

Interim Model Year Design Changes

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

Special Tools

Illustration Tool Number/Description CH-50342 Threaded Rod DT-113-2-A J-03289-20 KM-113-2-A Holding Fixture DT-8092 DW340-010 GE-8092 J-8092 KM-J-8092 Driver Handle DT-08614-A J-08614-A Pinion Flange Holder and Remover DT-26941 J-26941 Bushing and Bearing Remover - 3- 4 in. DT-29369-1 J-29369-1 Bushing and Bearing Remover DT-36842 J-36842 Transaxle Holding Fixture DT-36850 J-36850 Transjel Lubricant DT-41819 J-41819 Input Shaft Seal Installer DT-44873-2 J-44873-2 Shoulder Bolts DT-45124 J-45124 Removal Bridge DT-45756 J-45756 Rear Output Shaft Seal Installer DT-50839 Adapter Plate Bushing Remover and Installer DT-50840 Input Shaft Seal Installer DT-50937 Seal Protector DT-50985 Seal Installer GE- 28431-6 J-28431-6 Florescent Oil Dye - 6 1 oz. GE-42220 J-42220 High-Intensity Black Light Kit

Scheme 39

Scheme 39: Special Tools
Scheme 39: Special Tools

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