Transfer Case - Bw 4481-nr3 Cadillac Escalade GMT800

Specifications

Torque Specifications

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Diagnostic Starting Point - Transfer Case

Begin the system diagnosis by reviewing the SYMPTOMS - TRANSFER CASE . The SYMPTOMS - TRANSFER CASE will provide the following information

1. The required visual/physical inspections
2. The list of symptoms

Use the STRATEGY BASED DIAGNOSIS in General Information in order to identify the correct procedure for diagnosing the system.

Strategy Based Diagnostics

Review the system operation in order to familiarize yourself with the system functions. Refer to TRANSFER CASE DESCRIPTION AND OPERATION .

Visual/Physical Inspection

1. Inspect the easily accessible or visible system components for obvious damage, or for conditions which could cause the symptom.
2. Inspect the transfer case for the proper fluid. Refer to «TRANSFER CASE FLUID REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .

Symptom List

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

1. Transfer Case Popping Noise See «Transfer Case Popping Noise Symptom»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)
2. Transfer Case Whine or Rumble Noise See «Transfer Case Whine Or Rumble Noise Symptom»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)
3. Transfer Case Growl or Grinding Noise See «Transfer Case Growl Or Grinding Noise Symptom»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)
4. Transfer Case Shudder or Binding See «Transfer Case Shudder Or Binding Symptom»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)
5. Transfer Case Clunk during Acceleration and Deceleration See «Transfer Case Clunk During Acceleration And Deceleration Symptom»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)
6. Transfer Case Leak Diagnosis See «Transfer Case Leak Diagnosis»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3)

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1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transfer case shield bolts, if equipped.
3. Remove the transfer case shield, if equipped.

Scheme 24

1. Position the transfer case shield, if equipped. NOTE: Refer to «FASTENER NOTICE»(/cadillac/escalade/gmt800-2001-2006/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the transfer case shield bolts, if equipped. Tighten Tighten the bolts to 20 N.m (15 lb ft).
3. Lower the vehicle.

Removal Procedure

Important: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs.

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1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
3. Remove the fill plug.
4. Remove the drain plug. Important: Ensure that an approved drain pan is used when draining the transfer case.
5. Allow the transfer case to drain completely.

Installation Procedure

Important: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case.

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1. Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the drain and fill plugs. NOTE: Refer to «FASTENER NOTICE»(/cadillac/escalade/gmt800-2001-2006/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
2. Install the drain plug. Tighten Tighten the plug to 25 N.m (18 lb ft).
3. Fill the transfer case to the bottom of the fill plug hole with DEXRON®(R)-III, GM P/N 12346143, (Canadian P/N 10952622).
4. Install the fill plug. Tighten Tighten the plug to 25 N.m (18 lb ft).
5. Install the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
6. Lower the vehicle.

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1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Disconnect the speed sensor electrical connector (4).
3. Remove the speed sensor and O-ring.
4. Discard the O-ring.

Note. Refer to FASTENER NOTICE in Cautions and Notices.

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1. Install the speed sensor with a NEW O-ring. Tighten Tighten the sensor to 17 N.m (13 lb ft).
2. Connect the speed sensor electrical connector (4).
3. Lower the vehicle.

Tools Required

1. J 8092 Driver Handle
2. J 43484 Output Shaft Seal Installer

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1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
3. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft. Important: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft.
4. Remove the front output shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
5. Pry the inner seal race forward.
6. Using a small pry bar, move the inner seal race forward on the front output shaft.
7. Remove the inner seal race from the front output shaft.
8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case.
9. Remove the remaining part of the output shaft seal from the transfer case.

Scheme 36

1. Install the J 43484 (2) to the J 8092 (1).
2. Install a NEW seal onto J 43484 .
3. Using J 43484 (2), and J 8092 (1), install the seal.
4. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
5. Check the fluid level. Add fluid, if necessary.
6. Install the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
7. Lower the vehicle.

J 45756 Output Shaft Seal Installer

Scheme 37

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
3. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
4. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver.

Scheme 38

1. Using J 45756 , install a NEW front output shaft seal.
2. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
3. Check the fluid level. Add fluid, if necessary.
4. Install the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
5. Lower the vehicle.

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1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(/cadillac/escalade/gmt800-2001-2006/remont/hoistjack/#jacking-and-lifting-avalanche__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
3. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
4. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
5. Drain the fluid from the transfer case.
6. Disconnect the speed sensor electrical connector (4).
7. Remove the clip (3) from the transfer case bracket.
8. Reposition the speed sensor wire.
9. Remove the clips (5, 6) from the fuel pipe bracket.
10. Remove the fuel pipe clip from the fuel pipe bracket .
11. Support the transmission with a suitable jack stand.
12. Remove the transmission mount nuts.
13. Remove the crossmember bolts.
14. Remove the crossmember.
15. Install a suitable transmission jack to the transfer case.
16. Remove the transfer case adapter nuts.
17. Remove the fuel pipe bracket from the studs. Important: Pull straight back on the transfer case in order to position the transfer case so that it can be rotated parallel to the transmission.
18. Remove the transfer case from the adapter.
19. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
20. Lower the transfer case.
21. Remove the gasket from the transfer case.
22. Remove the transfer case from the transmission jack.

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1. Install the transfer case onto a suitable transmission jack. Important: When installing a new transfer case gasket, the gasket must be installed with the tab oriented up, and the yellow printing towards to front of the vehicle. Install the gasket without the use of any type of sealant or of lubricant.
2. Install a NEW transfer case gasket.
3. Rotate the transfer case so that it is parallel to the torsion bar mounting bracket.
4. Raise the transfer case into position.
5. Rotate the transfer case so that it is aligned with the adapter.
6. Install the transfer case to the adapter.
7. Install the fuel pipe bracket onto the studs. NOTE: Refer to «FASTENER NOTICE»(/cadillac/escalade/gmt800-2001-2006/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices. Important: Ensure that the gasket is flush to the transmission prior to installing the nuts.
8. Install the transfer case adapter nuts. Tighten Tighten the nuts to 50 N.m (37 lb ft).
9. Position the crossmember.
10. Install the crossmember bolts. Tighten Tighten the bolts to 70 N.m (52 lb ft).
11. Install the transmission mount nuts. Tighten Tighten the nuts to 40 N.m (30 lb ft).
12. Remove the jack stand from the transmission.
13. Install the fuel pipe clip to the fuel pipe bracket.
14. Install the clips (5, 6) to the fuel pipe bracket.
15. Position the speed sensor wire.
16. Install the clip (3) to the transfer case bracket.
17. Connect the speed sensor electrical connector (4).
18. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
19. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
20. Fill the transfer case with fluid.
21. Install the transfer case shield, if equipped. Refer to «TRANSFER CASE SHIELD REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
22. Lower the vehicle.

Scheme 47

1. Remove the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .
2. Remove the transfer case adapter bolts.
3. Remove the adapter.
4. Remove the adapter seal.

Important: Always use a new seal for the adapter. Do not use any type of sealant or adhesive in place of or with the seal.

Scheme 48

1. Install a NEW seal onto the adapter. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.
2. Install the adapter. NOTE: Refer to «FASTENER NOTICE»(/cadillac/escalade/gmt800-2001-2006/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) in Cautions and Notices.
3. Install the adapter bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft).
4. Install the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .

1. J 36825 Output Shaft Oil Seal Remover
2. J 23907 Slide Hammer with Bearing Adapter
3. J 42738 Front Output Shaft Seal Installer

Scheme 49

1. Remove the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) . Important: It may be necessary to use a sharp punch in order to poke a hole into the seal prior to inserting J 36825 .
2. Using J 23907 (1), and J 36825 (2), remove the input seal.

Scheme 50

1. Using J 42738 , install the input shaft seal.
2. Install the transfer case. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(/cadillac/escalade/gmt800-2001-2006/remont/transfer-case/#transfer-case-bw-4481-nr3) .

Transfer Case Description and Operation

The Borg Warner (BW) model 4481, RPO NR3 transfer case is a one-speed, full time, all wheel drive (AWD), transfer case. The transfer case provides power to both axles, through an external planetary type differential, which has two different sets of pinion gears. The planetary differential provides a 40/60 torque split, front/rear, full time. This means both axles are constantly being driven for maximum traction in all conditions.

The transfer case external type planetary differential functions the same as a typical rear axle differential. The transfer case differential pinion gears function as the spider gears, and the sun gears function as the side gears.

The following actions occur because of the planetary differential

1. If the vehicle is on a hoist, the front propeller shaft can be rotated by hand.
2. The vehicle cannot be driven if one propeller shaft is removed.
3. Operating the vehicle on the hoist can damage the differential pinion gears, by over-spinning.
4. Operating the vehicle with one propeller shaft removed causes over-spinning of the differential pinion gears.

The BW 4481 design of the planetary differential allows the use with the Vehicle Stability Enhancement System (VSES) vehicles. The VSES takes use of the planetary differential, by applying braking to a tire that has less traction and dividing the engine torque to the other axle.

The BW 4481 case halves are high-pressure, die-cast magnesium. Ball bearings support the input shaft, the front output shaft, and the rear output shaft. The transfer case requires DEXRON®(R) III ATF GM P/N 12346143 (Canadian P/N 10952622), which is red in color.

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When the BW 4481 is operating in the AWD mode, the power flows from the transmission to the transfer case input shaft (1). The input shaft (1) delivers the power to the planetary differential (4). The case of the planetary differential (4) is splined to the input shaft (1). The planetary differential (4) splits the torque 40 percent through the front differential pinion gears (3) to the front sun gear (8). The front sun gear (8) is engaged with the drive sprocket (2), which drives the chain (9) to the front output shaft (10), and power is delivered to the front propeller shaft. 60 percent of the torque to the rear output shaft (6) goes through the rear differential pinion gears (7) and rear sun gear (5), which is connected to the rear output shaft (6) and to the rear propeller shaft.

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See also:
• STRATEGY BASED DIAGNOSIS
• LIFTING AND JACKING THE VEHICLE
• FASTENER NOTICE
• SYMPTOMS - TRANSFER CASE
• TRANSFER CASE DESCRIPTION AND OPERATION