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Transfer Case - Graziano Buick LaCrosse II

Transfer Case 30 illustrations ~5277 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Support Bracket Fastener
First Pass5 N.m44 lb in
Second Pass60 N.m44 lb ft
Support Bracket to Engine Fasteners, LDK/A20NHT and LBY/A20DTR60 N.m44 lb ft
Support Bracket to Engine Fasteners, LBW/A28NET22 N.m16 lb ft
Transfer Case Fasteners110 N.m81 lb ft
Transfer Case Fill Plug50 N.m37 lb ft
Transfer Case Oil Drain Plug50 N.m37 lb ft
Transfer Case Rear Output Shaft Flange Bolts
First Pass20 N.m15 lb ft
Second Pass30°
Transfer Case Rear Extension Bolts
First Pass20 N.m15 lb ft
Second Pass30°
Transfer Case Vent Pipe Bolt22 N.m17 lb ft

Fastener Tightening Specifications

Approximate Fluid Capacities

ApplicationSpecification
MetricEnglish
Oil- Transfer Case0.66 L0.69 qt

Approximate Fluid Capacities

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
Transfer Case OilLubricant9218490088862826
Transfer Case-to-Rear Extension Housing Sealing SurfacesSealant888614179982257
Transfer Case Rear Extension Housing BoltThreadlocker1234549310953488
Transfer Case Rear Extension Housing Bolt HolesCleaner8886265088901247

Adhesives, Fluids, Lubricants, and Sealers

Scheme 1

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

Scheme 2

Scheme 2: Transfer Case Seal View
Scheme 2: Transfer Case Seal View
CalloutComponent Name
1Transfer Case-to-Transmission Seal

Scheme 3

Scheme 3: Vent Hose Assembly- 2nd Design
Scheme 3: Vent Hose Assembly- 2nd Design
CalloutComponent Name
1Vent Hose Assembly
2Clip
3O-ring
4Bolt

Strategy Based Diagnostics

Review the system operations in order to familiarize yourself with the system functions. Refer to Transfer Case Disassembled View . 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/lacrosse/ii-2009-2013/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__checking-aftermarket-accessories) .
  2. Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom.
  3. Inspect for the correct lubricant levels and the proper viscosities.
  4. Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed, road conditions, ambient temperature, and other specifics.
  5. Compare the driving characteristics or sounds, if applicable, to a known good vehicle and ensure you are not trying to correct a normal condition.

Intermittent

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

Symptom List

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

  1. «Diagnostic System Check - Vehicle»(/buick/lacrosse/ii-2009-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures)
  2. «Noisy in Drive»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__noisy-in-drive)
  3. «Noisy When Coasting»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__noisy-when-coasting)
  4. «Intermittent Noise»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__intermittent-noise)
  5. «Constant Noise»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__constant-noise)
  6. «Transfer Case Leak Diagnosis»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__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 lubricantReplace the lubricant and flush the transfer case of the contaminated fluid.
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Propeller Shaft Replacement .
Worn axle shaft constant velocity jointsReplace the constant velocity joints, as required.
Worn bearing in the differential assemblyRepair or replace the assembly.
Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a transmission shift occurs is not within the transfer case. A grinding noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A grinding noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission shift occurs is not within the transfer case. A whine noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A whine noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, 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 case case.Replace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Worn propeller shaft constant velocity jointsReplace the propeller shaft assembly. Refer to Propeller Shaft Replacement
Worn axle shaft constant velocity jointsReplace the constant velocity joints, as required.
Worn bearing in the differential assemblyRepair or replace the assembly as required.
Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a transmission shift occurs is not within the transfer case. A grinding noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A grinding noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission shift occurs is not within the transfer case. A whine noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A whine noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, 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 case case.Replace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Transfer case bearing or rear drive axle clutch module. A chatter or racheting type noise during hard acceleration on tight turns.Confirm noise is coming from the transfer case or the rear drive axle clutch module. Repair as required.

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 the propeller shaft assembly. Refer to Propeller Shaft Replacement .
Worn bearing in the differential assemblyRepair or replace the assembly as required.
Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a transmission shift occurs is not within the transfer case. A grinding noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A grinding noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, as required.
Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission shift occurs is not within the transfer case. A whine noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A whine noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires.Inspect for the proper fluid level. Fill, as required. Identify the location of the noise using the J 39570 Chassis Ears. If the noise continues, repair or replace components, 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 valve or hose assemblyReplace the ventilation valve or hose assembly, as required.
Leaking at the transfer case left side weep hole A transmission oil leak at the transfer case weep hole area may be caused by the front input shaft (outer) seal. A gear oil leak at the transfer case weep hole area may be caused by the front input shaft (inner) seal.Remove transfer case, disassemble and replace both front input shaft seals. Use care during reinstallation of the front input shaft to avoid damaging the sealing surfaces. Cover the shaft splines as required. If the leak is transmission-to-transfer case interface O-ring related, do not replace the transfer case input shaft seals.
Leaking at the right side axle shaft-to-intermediate shaft bearing location A transmission oil leak at the right side axle shaft-to-intermediate shaft bearing location may be caused by the intermediate shaft seal. A gear oil leak at the right side axle shaft-to-intermediate shaft bearing location may be caused by the rear input shaft seal.Identify the type of oil leak. Replace the intermediate shaft seal or rear input shaft seal as required.
Leaking at rear output shaft area. A leak at rear output shaft area is caused by either the rear output shaft seal or the rear output shaft housing O-ring seal.Inspect and replace either the rear output shaft or O-ring seal as required.
Leaking at transaxle assembly-to-transfer case interface A transmission oil leak at the transmission-to-transfer case interface may be caused by the transmission-to-transfer case O-ring seal.Replace the transmission-to-transfer case O-ring seal as required.
Case half seam leakDisassemble the case halves, clean and apply new RTV sealant to the sealing surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Leaking through caseInspect for a cracked case. Inspect for case porosity. Replace the transfer case
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.

Transfer Case Leak Diagnosis

Removal Procedure

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/lacrosse/ii-2009-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove and DISCARD the oil drain plug (1) and seal.
  3. Remove and DISCARD the fill plug (1) and seal.
  4. Allow the transfer case to drain completely.

Installation Procedure

  1. Install a NEW drain plug (1) and seal and tighten to 50 N.m (37 lb ft).
  2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
  3. Install a NEW fill plug (1) and seal and tighten to 50 N.m (37 lb ft).
  4. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/lacrosse/ii-2009-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove and DISCARD the oil drain plug (1) and seal.
  3. Remove and DISCARD the fill plug (1) and seal.
  4. Allow the transfer case to drain completely.
  1. Install a NEW drain plug (1) and seal and tighten to 50 N.m (37 lb ft).
  2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
  3. Install a NEW fill plug (1) and seal and tighten to 50 N.m (37 lb ft).
  4. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/lacrosse/ii-2009-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove and DISCARD the oil drain plug (1) and seal.
  3. Remove and DISCARD the fill plug (1) and seal.
  4. Allow the transfer case to drain completely.
  1. Install a NEW drain plug (1) and seal and tighten to 50 N.m (37 lb ft).
  2. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
  3. Install a NEW fill plug (1) and seal and tighten to 50 N.m (37 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/lacrosse/ii-2009-2013/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove and DISCARD the fill plug (1) and seal.
  1. Install a NEW fill plug (1) and seal and tighten to 50 N.m (37 lb ft).
  2. Lower the vehicle.

Front Output Shaft Seal Replacement

Special Tools

DT-48076 Bearing Installer

For equivalent regional tools, refer to the appropriate regional tools supplier or catalogue.

  1. Remove the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.
  2. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the first design dirt deflector and remove with suitable pliers.
  3. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool and then remove the outer portion by installing a sheet metal screw into surface and removing with suitable pliers. Refer to the appropriate regional tools supplier or catalogue for additional information.
  4. Discard the seal assembly (1).
  1. Install the first design dirt deflector (1) using the DT-48076 installer. Refer to the appropriate regional tools supplier or catalogue for additional information.
  2. Install the second design front wheel drive intermediate shaft dirt deflector (1) - model dependent using the DT 50768 seal installer (2) and J 8092 driver handle (3). Refer to the appropriate regional tools supplier or catalogue for additional information.
  3. Install the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.

Scheme 4

Scheme 4: Rear Output Shaft Seal Replacement
Scheme 4: Rear Output Shaft Seal Replacement
CalloutComponent Name
Preliminary Procedure 1. Remove the propeller shaft. Refer to Propeller Shaft Replacement . 2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement .
1Dust Shield Procedure Install the dust shield using DT-49095 installer. Special Tools DT-49095 Seal Installer
2Rear Output Shaft Seal Procedure Install the shaft seal using DT-49097 installer and DT-49061 cone. Special Tools DT-49061 Entry Cone DT-49097 Seal Installer

Rear Output Shaft Seal Replacement

Special Tools

  1. DT-113-2-A Holder
  2. DT-622-A Transmission Bracket
  3. DT-48076 Bearing Installer
  4. DT-49104 Protective Collar

For equivalent regional tools, refer to Special Tools .

  1. Remove the transfer case from the vehicle. Refer to «Transfer Case Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  2. Secure the transfer case (3) in DT-113-2-A holder (1), using the DT-622-A bracket (2).
  3. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the first design dirt deflector and remove with suitable pliers.
  4. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool and then remove the outer portion by installing a sheet metal screw into surface and removing with suitable pliers. Refer to «New Product Information»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__new-product-information) for additional information.
  5. Discard the seal assembly (1).
  6. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  7. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.
  8. Remove the bearing, if necessary. Refer to front wheel drive intermediate shaft in «Transfer Case Disassemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  2. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft using the DT-48076 installer (3) and a rubber mallet.
  3. Remove the DT-49104 protective collar (1).
  4. Apply grease to the output splines (1) of the intermediate shaft.
  5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  6. Install the first design dirt deflector (1) using the DT-48076 installer. Refer to the appropriate regional tools supplier or catalogue for additional information.
  7. Install the second design front wheel drive intermediate shaft dirt deflector (1) - model dependent using the DT 50768 seal installer (2) and J 8092 driver handle (3). Refer to the appropriate regional tools supplier or catalogue for additional information.
  8. Install the transfer case in the vehicle. Refer to «Transfer Case Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .

Special Tools

  1. DT-48076 Bearing Installer

For equivalent regional tools, refer to Special Tools .

  1. Remove the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.
  2. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the first design dirt deflector and remove with suitable pliers.
  3. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool and then remove the outer portion by installing a sheet metal screw into surface and removing with suitable pliers. Refer to «Transfer Case Disassemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) for additional information.
  4. Discard the seal assembly (1).
  1. Install the first design dirt deflector (1) using the DT-48076 installer. Refer to «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) for additional information.
  2. Install the second design front wheel drive intermediate shaft dirt deflector (1) - model dependent using the DT 50768 seal installer (2) and J 8092 driver handle (3). Refer to «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) for additional information.
  3. Install the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.
  1. Remove the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.
  2. Remove the second design intermediate shaft O-ring (3), as required.
  1. Install the second design intermediate shaft O-ring (3), as required.
  2. Install the right wheel drive shaft. Refer to the appropriate regional tools supplier or catalogue.
  1. DT-113-2-A Holder
  2. DT-622-A Transmission Bracket
  3. DT-48076 Bearing Installer
  4. DT-49104 Protective Collar

For equivalent regional tools, refer to Special Tools .

  1. Remove the transfer case from the vehicle. Refer to «Transfer Case Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  2. Secure the transfer case (3) in DT-113-2-A holder (1), using the DT-622-A bracket (2).
  3. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the first design dirt deflector and remove with suitable pliers.
  4. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool and then remove the outer portion by installing a sheet metal screw into surface and removing with suitable pliers. Refer to «New Product Information»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__new-product-information) for additional information.
  5. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  6. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.
  7. Remove the bearing, if necessary. Refer to front wheel drive intermediate shaft in «Transfer Case Disassemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  2. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft using the DT-48076 installer (3) and a rubber mallet.
  3. Remove the DT-49104 protective collar (1).
  4. Apply grease to the output splines (1) of the intermediate shaft.
  5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  6. Install the first design dirt deflector (1) using the DT-48076 installer. Refer to «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) for additional information.
  7. Install the second design front wheel drive intermediate shaft dirt deflector (1) - model dependent using the DT 50768 seal installer (2) and J 8092 driver handle (3). Refer to «Transfer Case Assemble»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) for additional information.
  8. Install the transfer case in the vehicle. Refer to «Transfer Case Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  1. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/lacrosse/ii-2009-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  2. Drain the oil from the transmission. Refer to «Transmission Fluid Drain and Fill»(/buick/lacrosse/ii-2009-2013/remont/automatic-trans/#automatic-transmission-6t70-repair-instructions-on-vehicle) .
  3. Remove the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement (GNB)»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement-gnb) , «Front Wheel Drive Shaft Replacement (GNA)»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement-gna) .
  4. Remove the transmission rear mount bracket. Refer to «Transmission Rear Mount Replacement (AWD)»(/buick/lacrosse/ii-2009-2013/remont/automatic-trans/#automatic-transmission-6t70-repair-instructions-on-vehicle) , «Transmission Rear Mount Replacement (FWD)»(/buick/lacrosse/ii-2009-2013/remont/automatic-trans/#automatic-transmission-6t70-repair-instructions-on-vehicle) .
  5. Remove the front catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (LFX-Front)»(/buick/lacrosse/ii-2009-2013/remont/exhaust/#engine-exhaust-system) , and «Catalytic Converter Replacement - Right Side (LFX-Rear)»(/buick/lacrosse/ii-2009-2013/remont/exhaust/#engine-exhaust-system) .
  6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).
  7. Remove the transfer case support bracket-to-transfer case bolts (2).
  8. Remove the transfer case support bracket-to-engine bolts (3).
  9. Remove the support bracket (1).
  10. Support the transfer case with a suitable jack, and secure with suitable straps.
  11. Remove the transfer case-to-transmission center bolt. The center bolt (3) is accessed through the opening in the center of the transfer case.
  12. Remove the remaining transfer case-to-transmission bolts (2).
  13. Separate the transfer case (1) from the transmission and remove the transfer case.
  1. Clean the contact surfaces between the transfer case and the transmission. Install a new transfer case-to-transmission O-ring (1).
  2. Support the transfer case with a suitable jack, and secure with suitable straps.
  3. Raise and align the transfer case in the correct position in relation to the transmission.
  4. Install the transfer case (1) to the transmission.
  5. Install the transfer case-to-transmission bolts (2).
  6. Install the transfer case-to-transmission center bolt. The center bolt is accessed through the opening in the center of the transfer case.
  7. Tighten the bolts (3) to 110 (81 lb ft).
  8. Install the support bracket (1).
  9. Install the transfer case support bracket-to-transfer case bolts (2).
  10. Install the transfer case support bracket-to-engine bolts (3).
  11. Install the support bracket between the transfer case and the engine carefully in three steps to avoid breakage. Tighten the support bracket-to-transfer case bolts (2) to 5 (44 lb in). Tighten the support bracket-to-engine bolts (3) to 60 (44 lb ft). Tighten the support bracket-to-transfer case fasteners (1) to 60 (44 lb ft).
  12. Install the transmission rear mount bracket.
  13. Install the transfer case vent hose (2), strap (1), and bolt (3).
  14. Tighten the transfer case vent hose bolt, if equipped, to 22 (17 lb ft).
  15. Install the front catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (LFX-Front)»(/buick/lacrosse/ii-2009-2013/remont/exhaust/#engine-exhaust-system) , and «Catalytic Converter Replacement - Right Side (LFX-Rear)»(/buick/lacrosse/ii-2009-2013/remont/exhaust/#engine-exhaust-system) .
  16. Install the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement (GNB)»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement-gnb) , «Front Wheel Drive Shaft Replacement (GNA)»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts__front-wheel-drive-shaft-replacement-gna) .
  17. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/lacrosse/ii-2009-2013/remont/driveshaft-universal-joints/#propeller-shaft) .
  18. Check the fluid level in the transfer case. Refer to «Transfer Case Fluid Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  19. Fill the transmission with oil. Refer to «Transmission Fluid Drain and Fill»(/buick/lacrosse/ii-2009-2013/remont/automatic-trans/#automatic-transmission-6t70-repair-instructions-on-vehicle) .
  20. Fill the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  1. Remove the transfer case from the vehicle. Refer to the appropriate regional tools supplier or catalogue.
  2. Remove and DISCARD the transfer case-to-transmission seal (1).
  1. Install the NEW transfer case-to-transmission seal (1).
  2. Install the transfer case in the vehicle. Refer to the appropriate regional tools supplier or catalogue.

Front Wheel Drive Shaft Seal Replacement - Right Side

Special Tools

DT-50768 Seal Installer

For equivalent regional tools, refer to Special Tools .

  1. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  2. Remove the intermediate drive shaft. Refer to «Intermediate Shaft Replacement»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts) .
  3. Install a sheet metal screw (2) into outer surface of the dirt deflector and grease seal assembly and remove with suitable pliers.
  4. Discard the dirt deflector and grease seal assembly (1).
  1. Install the NEW shaft dirt deflector and grease seal assembly (1) using the DT-50768 installer.
  2. Install the intermediate drive shaft. Refer to «Intermediate Shaft Replacement»(/buick/lacrosse/ii-2009-2013/remont/axle-shafts/#wheel-drive-shafts) .
  3. Fill the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano) .
  1. DT-113-A Bracket
  2. DT-307-B Remover Plate
  3. DT-622-A Adapter

For equivalent regional tools, refer to Special Tools .

Scheme 5

Scheme 5
Scheme 5

Secure the transfer case (3) in DT-113-A bracket (1), using the DT-622-A adapter (2).

Scheme 6

Scheme 6: Drain Plug Removal
Scheme 6: Drain Plug Removal

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

Scheme 7

Scheme 7: Fill Plug Removal
Scheme 7: Fill Plug Removal

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

Transfer Case Vent Removal

  1. Remove vent pipe bolt (1), if applicable.
  2. Remove transfer case vent pipe (2) and vent pipe seal (3), if applicable.

Scheme 8

Scheme 8: Transfer Case-to-Transmission Seal Removal
Scheme 8: Transfer Case-to-Transmission Seal Removal

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

Scheme 9

Scheme 9: Locating Bushing Removal
Scheme 9: Locating Bushing Removal

Remove the transfer case locating bushing (1) as required using multigrip pliers.

Intermediate Drive Shaft Removal

  1. Remove the front wheel drive intermediate shaft dirt deflector (1) - model dependent. Refer to «New Product Information»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__new-product-information) for additional information.
  2. Remove the intermediate drive shaft retaining ring (1).
  3. Remove the intermediate drive shaft (1), using a rubber mallet.

Intermediate Drive Shaft Bearing Removal

  1. Remove the transfer case intermediate gear bearing retaining ring (1).
  2. Remove the transfer case intermediate drive shaft bearing (1), using the DT-307-B remover plate (2) and a hydraulic press.
  3. Remove the transfer case intermediate gear bearing retaining ring (2) as required.

Scheme 10

Scheme 10: Rear Output Shaft Seal Dirt Deflector Removal
Scheme 10: Rear Output Shaft Seal Dirt Deflector Removal

Remove the rear output shaft seal dirt deflector (1), using a screw driver.

Rear Output Drive Shaft Seal Removal

  1. Install a sheet metal type screw (2) into the face of the rear output seal.
  2. Remove the rear output drive shaft seal (1) with multigrip pliers.

Rear Output Drive Shaft Housing O-ring Seal Removal

  1. Remove the 7 transfer case rear output drive shaft housing bolts (1).
  2. Remove the transfer case rear output drive shaft housing (2).
  3. Remove the transfer case rear output drive shaft housing seal (3).
  4. Clean all of the sealing surfaces.

Input Shaft Removal

  1. Remove the transfer case rear extension housing bolts (1) and rear extension housing (2).
  2. Remove the rear extension housing (2) from the transfer case housing (1).
  3. Remove the input shaft (1).
  4. Remove the intermediate drive shaft seal (2) from the input shaft.

Scheme 11

Scheme 11: Idler Shaft Removal
Scheme 11: Idler Shaft Removal

Remove the idler shaft (1) from the housing.

Input Shaft Seals Removal

  1. Remove the transfer case input shaft front (inner) seal (1) using a suitable screw driver.
  2. Remove the transfer case input shaft front (outer) seal (1) using a suitable screw driver.
  3. Remove the transfer case input shaft rear seal (1) from the rear extension housing.

Transfer Case Housing

  1. Clean the front case half in cleaning solvent and air dry.
  2. Inspect the housing for the following: Damage to threaded bolt holes (1 and 2) Damaged sealing surfaces (3) Bearing races (5) with wear or pitting Porosity External Damage

Rear Extension Housing

  1. Clean the rear case half in cleaning solvent and air dry.
  2. Inspect the housing for the following: Damaged sealing surfaces (1) Damage to threaded bolt holes (2) Bearing races (3) with wear or pitting Porosity External Damage

Input Shaft

  1. Clean the input shaft in cleaning solvent.
  2. Inspect the input shaft splines (1) for excessive wear or damage.
  3. Inspect the input shaft seal surfaces (2 and 5) for excessive grooves, rust, pitting or damage.
  4. Inspect the input shaft gear teeth (4) for excessive war or damage.
  5. Inspect the intermediate shaft seal (6) surface for damage.

Idler Shaft

  1. Clean the idler shaft in cleaning solvent.
  2. Inspect the idler shaft gear teeth (2) for excessive wear or other damage.
  3. Inspect the bearing surfaces (1 and 3) for pitting, wear or other damage.

Rear Output Shaft

  1. Clean the rear output shaft in cleaning solvent.
  2. Inspect the idler shaft gear teeth (2) for excessive wear or damage.
  3. Inspect the bearing surfaces (1) for pitting, wear or other damage.

Input Shaft Seal Installation

Special Tools

  1. DT-305-1/KM-305-1 Remover/Installer
  2. DT-49093 Seal Installer
  3. DT-49094 Fitting Drift

For equivalent regional tools, refer to Special Tools .

  1. Install the input shaft front (inner) seal (1) to the transfer case using the DT-49093 installer (2) and DT-305-1/KM-305-1 remover/installer (3).
  2. Install the input shaft front (outer) seal (1) to the transfer case using the DT-49093 installer (2) and DT-305-1/KM-305-1 remover/installer (3).
  3. Install the input shaft rear seal (1) to the rear extension housing using the DT-49093 installer (2) and DT-305-1/KM-305-1 remover/installer (3).

Idler Shaft Installation

Install the idler shaft (1) to the housing.

Input Shaft Installation

Special Tools

DT-49094 Fitting Drift

For equivalent regional tools, refer to Special Tools .

  1. Install the input shaft seal (2), using the DT-49094 drift (3).
  2. Install the input shaft (1) to the housing.
  3. Apply 5 mm (0.2 in) bead of RTV to the sealing surface of the transfer case housing (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__adhesives-fluids-lubricants-and-sealers) .
  4. Install the rear extension housing (2) onto the transfer case housing.
  5. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (3). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__adhesives-fluids-lubricants-and-sealers) .
  6. Install the NEW transfer case-to-rear extension housing bolts (1). Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 30 N.m (22 lb ft). Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 60 degrees.

Rear Output Drive Shaft Housing O-ring Seal Installation

  1. Clean the transfer case rear output drive shaft housing bolt holes. Thread repair tool may be used to clean the threads of old threadlock material.
  2. Spray thread cleaner into holes. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__adhesives-fluids-lubricants-and-sealers) for recommended cleaners.
  3. Install the housing shim, as required.
  4. Install the transfer case rear output drive shaft housing seal (3).
  5. Install the transfer case rear output drive shaft housing (2) to the transfer case.
  6. Apply threadlock to the threads of the transfer case rear output drive shaft housing bolts (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__adhesives-fluids-lubricants-and-sealers) for recommended thread locking material.
  7. Install the NEW 7 transfer case rear output drive shaft housing bolts (1). Tighten the NEW 7 transfer case rear output drive shaft housing bolts a first pass to 20 N.m (15 lb ft). Tighten the NEW 7 transfer case rear output drive shaft housing bolts a second pass to 30 degrees.

Rear Output Drive Shaft Seal Installation

Special Tools

  1. DT-49061 Seal Pilot
  2. DT-49097-A Seal Installer

For equivalent regional tools, refer to Special Tools .

  1. Install the DT-49061 pilot (3) onto the rear output shaft nut (4).
  2. Place the rear output drive shaft seal (2) over the DT-49061 pilot and onto the rear output shaft housing.
  3. Install the rear output drive shaft seal (2) using the DT-49097 -A installer (1).

Rear Output Shaft Seal Dirt Deflector Installation

Special Tools

DT-49095 Fitting Drift

For equivalent regional tools, refer to Special Tools .

Scheme 12

Scheme 12: Rear Output Shaft Seal Dirt Deflector Installation
Scheme 12: Rear Output Shaft Seal Dirt Deflector Installation

Install the rear output shaft seal dirt deflector (1), using the DT-49095 drift.

Intermediate Drive Shaft Bearing Installation

Special Tools

DT-48076 Bearing Installer

For equivalent regional tools, refer to Special Tools .

  1. Install the transfer case intermediate drive shaft bearing retaining ring (2).
  2. Press on the intermediate drive shaft bearing to the intermediate drive shaft, using DT-48076 installer and a hydraulic press.
  3. Install the transfer case intermediate drive shaft bearing retaining ring (1).

Intermediate Drive Shaft Installation

Special Tools

  1. DT-113-2-A Bracket
  2. DT-622-A Adapter
  3. DT-49103 Fitting Drift
  4. DT-49104 Protective Collar

For equivalent regional tools, refer to Special Tools .

  1. Install the DT-49104 protective collar (1) to the intermediate drive shaft (2), and install the intermediate drive shaft (2) using the DT-49103 fitting drift (3) and a rubber mallet.
  2. Remove the DT-49104 protective collar and apply grease to the splines of the shaft. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__adhesives-fluids-lubricants-and-sealers) for the recommended grease.
  3. Install the transfer case intermediate shaft retaining ring (1).
  4. Install the front wheel drive intermediate shaft dirt deflector (1) - model dependent using the DT 50768 Seal Installer (2) and J 8092 Driver Handle (3). Refer to «New Product Information»(/buick/lacrosse/ii-2009-2013/remont/transfer-case/#transfer-case-graziano__new-product-information) for additional information.
  5. Remove the transfer case (3) from DT-622-A adapter (2) and DT-113-2-A bracket (1).

Locating Bushing Installation

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

Transfer Case-to-Transmission Seal Installation

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

Transfer Case Vent Installation

  1. Install transfer case vent pipe (2) with new seal (1) to transfer case, if applicable.
  2. Install transfer case vent bolt (3) and tighten to 22 N.m (17 lb ft), if applicable.

Fill Plug Installation

CAUTIONRefer to Fastener Caution .

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

Drain Plug Installation

CAUTIONRefer to Fastener Caution .

Install a NEW drain plug (1) and seal and tighten to 50 N.m (37 lb ft).

Scheme 13

Scheme 13: Transfer Case Identification
Scheme 13: Transfer Case Identification

The build variation of transfer case can be identified by the assembly part number (1) located on the rear output shaft housing of the transfer case. Refer to the table below for additional Build Variation information.

Transfer Case Build Variations

Early 2010 model year vehicles were built with either first or second design Graziano supplied assemblies. First design Graziano transfer cases have a pressed into the housing vent assembly. Second design Graziano transfer cases have a bolt-in remote vent hose assembly. Vehicles built later in 2010 model year were produced with one of two versions of the American Axle Manufacturing (AAM) supplied transfer case based on engine and transmission configuration. Both the AAM transfer cases have a bolt-in remote vent hose assembly. The table below will help you to understand the brand of transfer case and content within. It is important to understand which variation is being serviced because of the different internal and external components and service parts for each. The AAM assembly can be used to replace an earlier design Graziano assembly providing the correct ventilation components are also used.

Transfer Case SupplierTransfer Case Assembly Part NumberVent Assembly/Hose DesignEngine RPOTransmission RPOIncludes Idler Shaft w/O-ring seals
GrazianoRefer to electronic parts catalogVent assembly pressed into housingLF1MH4NO
GrazianoRefer to electronic parts catalogBolt in with remote vent hose assemblyLF1MH4NO
American Axle Manufacturing (AAM)Refer to electronic parts catalogBolt-in remote vent hose assemblyLAUMXEYES
American Axle Manufacturing (AAM)Refer to electronic parts catalogBolt-in remote vent hose assemblyLF1MH4NO

Scheme 14

Scheme 14: General Transfer Case Identification
Scheme 14: General Transfer Case Identification

The transfer case (1) is positioned in the right side of the vehicle and bolted to the transmission. Its primary function is to receive power from the transmission and transfer it using helical and hypoid gear sets to the rear differential via the propeller shaft. The internal intermediate shaft transfers power to the right-side front wheel.

Scheme 15

Scheme 15
Scheme 15

The transfer case (1) is fully mechanical with no internal or external electronic controls or sensors.

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

Scheme 16

Scheme 16: Housing and Cover
Scheme 16: Housing and Cover

The transfer case oil drain plug (1) is located at the front of the assembly.

Scheme 17

Scheme 17
Scheme 17

The transfer case housing (1) and rear extension housing (2) are produced from a high-pressure cast aluminum alloy. A number of reinforcement ribs are fitted in suitable locations to strengthen the transfer case assembly. These reinforcement ribs constitute a vital part of the cooling for the transfer case. The transfer case rear extension housing is retained to the transfer case housing with bolts (3). Two dowel pins locate the rear extension housing to the transfer case housing. The mating surfaces of transfer case housing and rear extension housing are sealed by RTV type sealant.

Scheme 18

Scheme 18
Scheme 18

The transfer case assembly is bolted to the transmission with four transfer case bolts. A locating bushing (2) on the transfer case housing ensures correct installation position. The sealing area between the transfer case housing and the transmission is sealed with serviceable O-ring (1). Two opposite radial seals seal the input shaft and prevent transmission and transfer case oil from mixing. If an input shaft seal failure occurs, the transmission and transfer case fluids will not mix as there is a weep hole in the transfer case housing between the two radial seals.

Scheme 19

Scheme 19
Scheme 19

A transfer case vent (2) is located on the top area of the transfer case housing. First design Graziano transfer cases have a pressed into the housing vent assembly. Second design Graziano transfer cases have a bolt-in remote vent hose assembly. Second design vent hose assemblies are routed to vent into the engine compartment. The oil drain plug (1) is magnetic. A mounting bracket retains the output end of the rear extension housing to the engine assembly.

Scheme 20

Scheme 20
Scheme 20

There are tapered bearing races (1) in the transfer case housing and rear extension housing (2) for the input shaft and idler shaft. Gear tooth clearances and bearing preloads are maintained by shims located behind the bearing races. There is a sealed ball bearing type intermediate shaft bearing (3) located in the rear extension housing.

The rear extension housing serves partly as a holder for the intermediate shaft bearing (3) and also as an attachment point for the transfer case to the engine.

Scheme 21

Scheme 21: Input Shaft
Scheme 21: Input Shaft

The input shaft splines (6) are mated to and driven by the transmission differential housing. The rotational speed of the input shaft is the same as the transmission output. Installed into the transfer case housing are two opposing input shaft front seals (5). The two input shaft front seals are designed to restrict transmission oil from entering the transfer case as well as restrict transfer case oil from entering the transmission. The opposite or rear end of the input shaft is sealed by the intermediate shaft seal (1)

The intermediate shaft seal (1) is installed into the output end of the rear extension housing and is designed to restrict oil, dirt, and debris from entering the transfer case. The helical gear teeth of the input shaft (3) are engaged to the helical gear teeth of the idler shaft. The input shaft is mounted in two tapered roller bearings (2, 4). The bearings are given the correct preload during assembly by means of shims being fitted behind the bearing races in the housing and cover.

Scheme 22

Scheme 22: Idler Shaft
Scheme 22: Idler Shaft

The idler gear consists of a helical gear (2) and a hypoid gear (3), has a hollow center, and is driven by the helical gear on the input shaft.

The idler hypoid gear (3) mates to and drives the hypoid gear on the rear output shaft. The input shaft, idler gear, and rear output shaft gear sets are precision machined and are not serviceable.

The idler gear is mounted in two tapered roller bearings (1 and 4). The bearings are given the correct preload and gears proper clearance during assembly by means of shims being fitted behind the bearing races in the housing and cover. If the shims are removed for any reason, the shims need to be reinstalled to their original locations.

Scheme 23

Scheme 23: Rear Output Shaft Flange
Scheme 23: Rear Output Shaft Flange

The rear output shaft housing (2) is bolted to the transfer case housing with 7 bolts (1) and is sealed to the transfer case housing with a serviceable O-ring (4) seal. A shim (3) adjusts the rear output shaft helical gear clearance to the helical gear of the idler shaft. The rear output shaft flange is hollow and is equipped with internal splines. The splines of the propeller shaft are mated to the rear output shaft. The spline of the propeller shaft is equipped with a spring-loaded retaining ring which retains the propeller shaft in the rear output shaft flange.

New Product Information

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

Changes may include one or more of the following items

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

Scheme 24

Scheme 24: Interim Model Year Design Change - Front Wheel Drive Intermediate Shaft Dirt Deflector
Scheme 24: Interim Model Year Design Change - Front Wheel Drive Intermediate Shaft Dirt Deflector

Interim 2012 model year, a new design front wheel drive intermediate shaft dirt deflector (1) was added to second design assemblies.

Product changes include

  1. Modifications to the extension housing at seal area
  2. Addition of a new cassette type dirt deflector (1)
  3. A new design IDS shaft with a revised surface finish on the OD area
  4. The release of a new deflector installer tool DT 50768 (2)

First design 2012 and earlier assemblies do not have the new design deflector or shaft. Second design 2012 and later assemblies do have the new design deflector and shaft. The new design deflector is not to be used in first design 2012 and earlier assemblies. The new design IDS shaft is interchangeable with the earlier design shaft and is back-serviceable.

The new deflector is to be installed using the DT 50768 (2) and the J 8092 (3).

Service replacement transfer case assemblies for older applications may include the new design components.

Scheme 25

Scheme 25
Scheme 25

Interim 2012 model year, a new design front wheel drive intermediate shaft dirt deflector was added to second design assemblies. First design 2012 and earlier assemblies can be identified as having open areas (2) at the end of the rear extension housing. The new design deflector is not to be used in first design 2012 and earlier assemblies.

Second design 2012 and later assemblies can be identified as not having open areas (1) at the end of the rear extension housing. The new design deflector is to be used in second design 2012 and later assemblies. Service replacement transfer case assemblies for older applications may include the new design components.

Illustration Tool Number/Description GE 8092 6-9606332 M-840911-A J-8092 Driver Handle DT-50768 Seal Installer DT-113-2-A J-03289-20 KM-113-2 Bracket DT-305-1 KM-305-1 J-42176 Driver Handle DT-307-B J-22912-B KM-307-B Remover Plate DT-622-A J-36842 KM-622-A Holder DT-48076 Bearing Installer DT-49061 Seal Pilot DT-49093 Seal Installer DT-49094 Fitting Drift DT-49095 Dust Cover Installer DT-49097-A Seal Installer DT-49103 Fitting Drift DT-49104 Protective Collar

Scheme 26

Scheme 26: Special Tools
Scheme 26: Special Tools

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30