Transfer Case - Bw 4485-nr3 — Cadillac Escalade GMT900 (2006-2014)

Approximate Fluid Capacities

Application	Specification
Application	Metric	English
DEXRON®VI GM P/N 88861003 (Canadian P/N 88861004)	1.4 liters	1.5 quarts

Fastener Tightening Specifications

Application	Specification
Application	Metric	English
Adapter Studs	10 N.m	89 lb in
Case Bolts	21 N.m	15 lb ft
Drain Plug	25 N.m	18 lb ft
Fill Plug	25 N.m	18 lb ft
Vent	6 N.m	53 lb in

Adhesives, Fluids, Lubricants, and Sealers

Application	Type of Material	GM Part Number
Application	Type of Material	United States	Canada
Drain Plug	Pipe Sealant	12346004	10953480
Fill Plug	Pipe Sealant	12346004	10953480
Front Output Shaft Cup Plug	Threadlocker	12345382	10953489
Rear Case Half to Front Case Half	RTV Sealant	12345739	10953541
Transfer Case Fluid	DEXRON®VI	88861003	88861004
Vent	Pipe Sealant	12346004	10953480

Scheme 1

Scheme 1: Transfer Case Disassembled View

Callout	Component Name
1	Adapter Stud
2	Front Case Half
3	Location Pin
3	Location Pin
4	Rear Output Shaft Bushing
5	Rear Output Shaft Seal
6	Shipping Seal
7	Fill Plug
8	Case Half Bolt
9	Wiring Harness Bracket
10	Drain Plug
11	Rear Case Half
12	Front Output Shaft Seal
13	Vent
14	Input Shaft Seal

Scheme 2

Callout	Component Name
1	Input Gear Bearing
2	Input Shaft
3	Drive Sprocket Bushing
4	Drive Sprocket
5	Drive Chain
6	Front Sun Gear
7	Planetary Differential Assembly
8	Rear Sun Gear Thrust Washer
9	Rear Sun Gear
10	Input Shaft Rear Support Bushing
11	Rear Output Shaft
12	Rear Output Shaft Bearing Outer Retaining Ring
13	Rear Output Shaft Bearing
14	Rear Output Shaft Bearing Retaining Ring
15	Front Output Shaft Rear Bearing
16	Driven Sprocket
17	Front Output Shaft Cup Plug
18	Front Output Shaft
19	Front Output Shaft Front Bearing

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

Inspect the easily accessible or visible system components for obvious damage, or for conditions which could cause the symptom.
Inspect the transfer case for the proper fluid. Refer to «Transfer Case Fluid Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .

Symptom List

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

«Transfer Case Popping Noise»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-popping-noise)
«Transfer Case Whine or Rumble Noise»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-whine-or-rumble-noise)
«Transfer Case Growl or Grinding Noise»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-growl-or-grinding-noise)
«Transfer Case Shudder or Binding»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-shudder-or-binding)
«Transfer Case Clunk During Acceleration and Deceleration»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-clunk-during-acceleration-and)
«Transfer Case Leak Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-leak-diagnosis)

Transfer Case Popping Noise

Cause	Correction
DEFINITION: A faulty internal transfer case component that causes a popping noise in the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Chain jump	Replace the chain and sprockets. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the shaft bearings. Refer to Transfer Case Disassemble and Transfer Case Assemble . Inspect for damaged components caused by metal debris. Refer to Transfer Case Disassemble and Transfer Case Assemble .

Transfer Case Whine or Rumble Noise

Cause	Correction
DEFINITION: A faulty internal transfer case component that causes a whine noise in the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Faulty bearings	Inspect all of the bearings and journals. Refer to Transfer Case Cleaning and Inspection . Replace any faulty bearings, and any components with faulty bearing journals. Refer to Transfer Case Disassemble and Transfer Case Assemble .

Transfer Case Growl or Grinding Noise

Cause	Correction
DEFINITION: A faulty internal transfer case component that causes a growl or grinding noise in the transfer case while the vehicle is turning. Review the Symptoms - Transfer Case and perform the necessary inspections.
Planetary differential	Inspect the planetary differential pinion gears for the following conditions: Chipped, bent or deformed teeth Pinion gear bushings worn Pinion gear thrust washers missing Seized or binding pinion gears Refer to Transfer Case Cleaning and Inspection . Inspect the planetary differential for deformation. Refer to Transfer Case Cleaning and Inspection . Replace the planetary differential assembly if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Sun gears	Inspect the sun gears for the following conditions: Gear tooth failure Worn or galled thrust surfaces Refer to Transfer Case Cleaning and Inspection . Replace the sun gears if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Thrust washer	Inspect the thrust washer for seizure to the planetary differential. Inspect the thrust washer for galling. Replace the thrust washer if faulty and the mating component if damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Planetary differential not timed properly	Inspect the planetary differential for being timed properly. Refer to Transfer Case Assemble . Properly time the planetary differential gears. Refer to Transfer Case Assemble .

Transfer Case Shudder or Binding

Cause	Correction
DEFINITION: A shudder, binding, or a crow-hop while turning, which may cause tire scuffing. Review the Symptoms - Transfer Case and perform the necessary inspections.
Planetary differential	Inspect the planetary differential pinion gears for the following conditions: Chipped, bent or deformed teeth Pinion gear bushings worn Pinion gear thrust washers missing Seized or binding pinion gears Refer to Transfer Case Cleaning and Inspection . Inspect the planetary differential for deformation. Refer to Transfer Case Cleaning and Inspection . Replace the planetary differential assembly if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Thrust washer	Inspect the thrust washer for seizure to the planetary differential. Replace the thrust washer if faulty and the mating component if damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Planetary differential not timed properly	Inspect the planetary differential for being timed properly. Refer to Transfer Case Assemble . Properly time the planetary differential gears. Refer to Transfer Case Assemble .

Transfer Case Clunk During Acceleration and Deceleration

Cause	Correction
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Incorrect fluid level or incorrect fluid	Inspect the transfer case for the correct fluid level. Refer to Transfer Case Fluid Replacement . Inspect the transfer case for the correct type of fluid. Flush the transfer case, and fill with the correct fluid, if required. Refer to Approximate Fluid Capacities .
Excessive clearance between the slip yoke and the rear output shaft	Inspect for the following conditions: Worn slip yoke splines Worn rear output shaft splines Repair or replace the following components if faulty. Replace the slip yoke, if required. Refer to Rear Propeller Shaft Replacement . Replace the rear output shaft, if required. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Excessive clearance between the slip yoke and the rear bushing	Inspect for the following conditions: Worn rear bushing Worn slip yoke bushing journal Repair or replace the following components if faulty. Replace the slip yoke, if required. Refer to Rear Propeller Shaft Replacement . Replace the rear case half if the rear bushing is worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Worn or faulty planetary differential	Inspect the planetary differential for the following conditions: Loose planetary differential splines to the input shaft splines Loose or faulty pinion gears Refer to Transfer Case Cleaning and Inspection . Replace the planetary differential assembly if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Worn or missing sun gear thrust washer	Inspect to ensure the thrust washer is installed. Inspect the thrust washer and mating surface for excessive wear. Replace the worn or missing thrust washer. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Worn or damaged rear sun gear	Inspect the sun gear external gear teeth for excessive wear. Inspect the sun gear to rear output shaft for excessive looseness. Replace the sun gear or rear output shaft if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Rear output shaft bearing outer retaining ring	Inspect for the following conditions: Proper installation of the rear output shaft bearing retaining ring Excessive wear or damaged retaining ring groove in the rear case half Repair or replace the following components if found faulty: Properly install a new rear output shaft bearing outer retaining ring. Replace the rear case half if the retaining ring groove is excessively worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .

Transfer Case Leak Diagnosis

Cause	Correction
DEFINITION: A visible indication of an external fluid leak from the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Drain plug or fill plug leak	Inspect for the correct sealer and the correct amount of sealer on the plugs. Install the plugs correctly. Refer to Transfer Case Fluid Replacement .
Rear output shaft seal leaking	Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked Rear output shaft bushing for excessive wear Slip yoke seal surface for wear or pitting Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to Transfer Case Fluid Replacement . Clean, or properly route the vent hose. Replace the slip yoke if the surface could cause leakage. Refer to Rear Propeller Shaft Replacement . Replace the rear case half if the bushing is worn. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the rear case half if the seal bore is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the rear output shaft seal. Refer to Rear Output Shaft Seal Replacement .
Front output shaft seal leaking	Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to Transfer Case Fluid Replacement . Clean or properly route the vent hose. Replace the front case half if the seal bore is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the front output shaft seal. Refer to Front Output Shaft Seal Replacement .
Leaking at the vent	Transfer case overfilled Inspect for the correct transfer case fluid level. Refer to Transfer Case Fluid Replacement . Inspect the transmission fluid level. Refer to Transmission Fluid Level and Condition Check . If the transmission fluid level is low, and the transfer case fluid level is too high, replace the transfer case input shaft seal. Refer to Input Shaft Seal Replacement . Inspect for the following conditions: Seal improperly installed, worn, or damaged Seal bore damaged or cracked Input shaft seal surface worn, grooved, or damaged Seal the vent with the correct sealer if leaking at the case. Refer to Transfer Case Assemble .
Transfer case to adapter leak	Inspect for the following conditions: Loose mounting fasteners Gasket or sealant faulty The transfer case input shaft seal leaking Repair or replace the following components if found faulty: Replace the transfer case input shaft seal. Refer to Input Shaft Seal Replacement . Inspect for the following: Seal improperly installed, worn, or damaged Seal bore damaged or cracked Input shaft seal surface worn, grooved, or damaged Repair or replace the loose fasteners. Refer to Transfer Case Adapter Replacement . Replace the transfer case gasket or sealer. Refer to Transfer Case Adapter Replacement .
Front case half to rear case half seam leak	Disassemble and seal the case halves. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Case leaking	Inspect for a cracked case or case porosity. Replace the faulty case half. Refer to Transfer Case Disassemble and Transfer Case Assemble .

Removal Procedure

Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
Remove the transfer case shield bolts (1, 3, and 4).
Remove the transfer case shield (2 or 5).

Installation Procedure

Position the transfer case shield (1, 3, and 4).
Install the transfer case shield bolts (2 or 5). Tighten: Tighten the bolts to 20 N.m (15 lb ft).
Lower the vehicle.

Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
Remove the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Remove the fill plug.
Remove the drain plug.
Allow the transfer case to drain completely.

Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs.
Install the drain plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
Fill the transfer case to the bottom of the fill plug hole with the recommended fluid.
Install the fill plug. Tighten: Tighten the plug to 25 N.m (18 lb ft).
Install the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Lower the vehicle.

Front Output Shaft Seal Replacement

Tools Required

J 8092 Driver Handle
J 43484 Output Shaft Seal Installer. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .

Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
Remove the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Remove the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) . 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.
Remove the front output shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
Pry the inner seal race forward.
Using a small pry bar, move the inner seal race forward on the front output shaft.
Remove the inner seal race from the front output shaft.
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.
Remove the remaining part of the output shaft seal from the transfer case.

Install the J 43484 (2) to the J 8092 (1). See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
Install a NEW seal onto J 43484 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
Using J 43484 (2), and J 8092 (1), install the seal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
Install the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Check the fluid level. Add fluid, if necessary.
Install the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Lower the vehicle.

Tools Required

J 45756 Output Shaft Seal Installer. See Special Tools .

Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
Remove the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Remove the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Remove the rear output shaft seal by prying it out with a flat tipped screwdriver.

Using the J 45756 , install a NEW front output shaft seal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
Install the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Check the fluid level. Add fluid, if necessary.
Install the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Lower the vehicle.

Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
Remove the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Remove the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Remove the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Drain the fluid from the transfer case.
Support the transmission with a suitable jack stand.
Remove the transmission mount nuts and bolts.
Remove the crossmember bolts.
Remove the crossmember.
Remove the transmission mount.
Install a suitable transmission jack to the transfer case.
Remove the transfer case adapter nuts.
Remove the fuel pipe bracket from the studs.
Remove the transfer case from the adapter.
Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
Lower the transfer case.
Remove the gasket from the transfer case.
Remove the transfer case from the transmission jack.

Install the transfer case onto a suitable transmission jack.
Install a NEW transfer case gasket.
Rotate the transfer case so that it is parallel to the torsion bar mounting bracket.
Raise the transfer case into position.
Rotate the transfer case so that it is aligned with the adapter.
Install the transfer case to the adapter.
Install the fuel pipe bracket onto the studs.
Install the transfer case adapter nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
Install the transmission mount.
Position the crossmember.
Install the crossmember bolts. Tighten: Tighten the bolts to 70 N.m (52 lb ft).
Install the transmission mount nuts and bolts. Tighten: Tighten the nuts and bolts to 40 N.m (30 lb ft).
Remove the jack stand from the transmission.
Install the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Install the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
Fill the transfer case with fluid.
Install the transfer case shield, if equipped. Refer to «Transfer Case Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Lower the vehicle.

Remove the transfer case. Refer to «Transfer Case Assembly Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Remove the transmission mount.
Remove the transfer case adapter bolts.
Remove the adapter.
Remove the adapter seal.

Install a NEW seal onto the adapter.
Install the adapter.
Install the adapter bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
Install the transmission mount.
Install the transfer case. Refer to «Transfer Case Assembly Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .

Input Shaft Seal Replacement

Tools Required

J 36825 Output Shaft Oil Seal Remover. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
J 23907 Slide Hammer with Bearing Adapter
J 42738 Front Output Shaft Seal Installer. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .

Remove the transfer case. Refer to «Transfer Case Assembly Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Using the J 23907 (1), and J 36825 (2), remove the input seal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .

Using the J 42738 , install the input shaft seal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__special-tools) .
Install the transfer case. Refer to «Transfer Case Assembly Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .

Transfer Case Disassemble

Special Tools

J 2619-01: Slide Hammer
J 3289-20: Holding Fixture
J 26941: Bushing and Bearing Remover - 3-4 inch
J 45124: Puller Bridge
J-45124-9: Puller Legs
J 45358: Case Spreader
J 45380: Transfer Case Rear Bushing Remover and Installer
J 45548: Mainshaft Support Bushing/Bearing Remover
J 45759: Assembly Fixture

For equivalent regional tools, refer to Special Tools

Attach the J 45759: assembly fixture to the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759: assembly fixture.
Mount the J 3289-20: holding fixture (1) to a sturdy workbench.
Install the J 45759: assembly fixture (2) into J 3289-20: holding fixture (1) and secure with pivot pin.
Remove the drain plug and the fill plug. Ensure all of the transfer case fluid is drained out of the transfer case.
Remove the front output shaft seal by inserting a flat-tip screwdriver behind the inner race of the seal.
Pry the inner seal race forward.
Using a small pry bar, move the inner seal race forward on the front output shaft.
Remove the inner seal race from the front output shaft.
Insert a flat-tip screwdriver or a small pry bar between the outer lip of the front output shaft seal and the transfer case.
Remove the remaining part of the front output shaft seal from the transfer case.
Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
Remove the transfer case retaining bolts and washers. Mark the location of the brackets.
Using the J 45358: case spreader between the tabs on the case halves, shear the sealer that is holding the case halves together.
Using pry bars at each side of the case, remove the case from the locating pins.
Remove the rear case half from the front case half. The rear output shaft will come with the rear case half.
Remove the rear sun gear.
Remove the sun gear thrust washer.
Remove the planetary differential assembly.
Remove the front sun gear.
Remove the chain with the drive sprocket and driven sprocket.
Remove the input shaft.
Remove the front output shaft assembly.
If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
Using a hammer and a suitable punch, remove the input seal.
Using the J 26941: bushing and bearing remover (3), the J 45124: puller bridge (1), and the J-45124-9: puller legs (2), remove the input shaft bearing for the front input shaft from the front case.
Using a brass drift, remove the front output shaft bearing from the front case half.
If necessary, remove the vent from the front case half.
Using J 45380: bushing remover and installer, remove the rear output shaft bushing.
Remove the rear output shaft from the rear case half. Spread the rear output shaft rear bearing outer retaining ring. Using a soft-face hammer, tap on the end of the rear output shaft.
Remove the retaining ring for the rear output shaft bearing.
Using a hydraulic press, remove the rear output shaft bearing.
Inspect the mainshaft rear support bushing in the rear output shaft for being faulty. Refer to «Transfer Case Cleaning and Inspection»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3) .
Using the J 2619-01: slide hammer (1) and the J 45548: bushing/bearing remover (2), remove the mainshaft rear support bushing from the rear output shaft.
Using the J 26941: bushing and bearing remover (3), the J 45124: puller bridge (1), and the J-45124-9: puller legs (2), remove the rear bearing for the front output shaft from the rear case.

Front Case Half

Clean the front case half in cleaning solvent and air dry.
Remove the metal shavings from the case half bolt holes.
Remove the sealer from the case sealing surfaces.
Inspect the case for being broken or cracked.
Inspect the front output shaft front bearing bore (5) for the following conditions: A spun bearing Cracks
Inspect the input shaft bearing bore (4) for the following conditions: A spun bearing Cracks
Replace the front case half if any of the above conditions are found.
Inspect the sealing surfaces (1) for damage.
Repair small scratches or nicks with a soft stone.
Inspect the front case to transmission case mounting surface for damage.
Inspect the case threaded bolt holes (2) for damage.
Repair any damaged threads.
Inspect the transmission to transfer case studs for damage.
Replace any damaged studs. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .
Inspect the location pins (3) for being loose or missing.
Repair or replace any damaged location pins.
Inspect the front output shaft front bearing and the input shaft bearing for the following conditions: Roughness Brinelling Pitting
Replace the bearings if any of the above conditions are found. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .

Rear Case Half

Clean the rear case half in cleaning solvent and air dry.
Remove the sealer from the case sealing surfaces.
Inspect the case for being broken or cracked.
Replace the case if it is broken or cracked.
Inspect the sealing surfaces (1) for damage.
Repair small scratches or nicks with a soft stone.
Inspect the case threaded bolt holes for damage.
Repair any damaged threads.
Inspect the front output shaft rear bearing bore (2) for the following conditions: Spun bearing Cracks
Inspect the rear output shaft rear bearing bore (4) for the following conditions: Spun bearing Cracks
Replace the case if the bearing has spun. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .
Inspect the retaining ring (5) for the rear output shaft rear bearing for being bent or twisted.
Replace a faulty retaining ring.
Inspect the rear output shaft bushing (3) for scoring or wear.
Replace the case if the rear output shaft bushing is faulty. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .
Replace the case if the control actuator lever shaft bore is faulty. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .

Differential Components

Clean the planetary differential in cleaning solvent. Do not disassemble the planetary differential.
Air dry and ensure all cleaning solvent is removed from the bearings in the pinion gears (3). Do not spin the pinion gears with compressed air.
Inspect the pinion gears for chipped teeth.
Inspect the pinion gears for debris embedded in the root of the teeth.
Inspect the pinion gears for excessive side movement from worn bushings or shafts.
Inspect the planetary housing for cracks at the web (1) of the housing.
Inspect the thrust washer surface (2) for scoring or excessive wear.
Inspect the planetary housing for distortion.
Inspect the planetary housing to mainshaft splines for excessive wear.
Replace the planetary differential if any of the above conditions are found.
Inspect the planetary thrust washers for excessive wear or scoring.
Replace the thrust washers if they are faulty.

Clean the front sun gear (1) and the rear sun gear (2) in cleaning solvent and air dry.
Inspect the teeth on the front sun gear (1) and the rear sun gear (2) for the following conditions: Chipped teeth Excessively worn gear surfaces Slight wear marks are normal. Debris embedded in the root of the teeth
Inspect the thrust washer surfaces for excessive wear or scoring.
Replace the front sun gear (1) and the rear sun gear (2) if they are faulty.

Drive Chain and Sprockets

Clean the drive chain (1), drive sprocket (2), and driven sprocket (3) in cleaning solvent and air dry.
Inspect the drive chain (1) for the following conditions: Loose link pins Binding or stiff links Debris embedded in the links Worn teeth surfaces
Replace the chain if any of the above conditions are found.
Inspect the driven sprocket (3) and the drive sprocket (2) for the following conditions: Chipped teeth Excessively worn gear surfaces Slight wear marks are normal. Debris embedded in the root of the teeth
Inspect the drive sprocket bushing for the following conditions: Excessive wear Scoring
Replace the sprockets if any of the above conditions are found. The chain and sprockets may be replaced separately.

Input Shaft

Clean the input shaft in cleaning solvent.
Inspect the input seal surface (1) for excessive grooves or damage.
Inspect the bearing journals on the input shaft for the following conditions: The drive gear bushing (2) The rear support bushing (4) Scoring Pitting Brinelling Excessive wear
Inspect the input shaft planetary carrier assembly splines (3) for damage or excessive wear. Witness marks at the location of the gear is normal.
Replace the input shaft if any of the above conditions are found.

Front Output Shaft

Clean the front output shaft in cleaning solvent and air dry.
Inspect for spun bearings at the front output shaft bearing areas.
Inspect the front output internal splines and driven gear splines for damage or excessive wear.
Replace the front output shaft if it is damaged.
Inspect the cup plug in the front output shaft for leaking.
Replace the cup plug if it is leaking. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .

Rear Output Shaft

Clean the rear output shaft with rear output shaft bearing in cleaning solvent.
Air dry and ensure all solvent is removed from the bearing.
Inspect the rear output shaft bearing for the following conditions: Scoring Pitting Brinelling Excessive wear
Replace the rear output shaft bearing if it is faulty. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .
Inspect the mainshaft rear support bushing for the following conditions: Pitted Wear Corrosion
Replace the mainshaft rear support bushing if any of the above conditions are found. Refer to «Transfer Case Disassemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/escalade/gmt900-2006-2014/remont/transfer-case/#transfer-case-bw-4485-nr3__transfer-case-assemble) .
Inspect the rear output shaft splines for wear or damage.
Inspect the rear output shaft bearing area for a spun bearing.
Replace the rear output shaft if any of the above conditions are found.

Transfer Case Assemble

Special Tools

J 3289-20: Holding Fixture
J 8092: Universal Driver
J 22912-B: Rear Pinion and Axle Bearing Remover
J 36850: Transjel Lubricant
J 42176: Universal Driver Handle - Non-Threaded
J 42738: Seal Installer
J 43484: Front Output Shaft Seal Installer
J 45380: Transfer Case Rear Bushing Remover and Installer Rear Output Shaft Seal Installer
J 45757: Mainshaft Support Bushing and Bearing Installer
J 45759: Assembly Fixture

For equivalent regional tools, refer to Special Tools

If removed, install the transfer case mounting studs. Tighten the mounting studs to 10 N.m (89 lb in).
Attach the J 45759: assembly fixture to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759: assembly fixture.
Install the J 45759: assembly fixture (2) into the J 3289-20: holding fixture (1) and secure with the pivot pin.
If the vent is removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
Install the vent.
Tighten the vent to 6 N.m (53 lb in).
Install the input shaft bearing in the front case half. Use a hammer and a brass drift only on the outer bearing race. Ensure the bearing is kept square to the bore while installing.
Install the front bearing, for the front output shaft, in the front case half. Use a hammer and a brass drift only on the outer bearing race. Ensure the bearing is kept square to the bore while installing.
If it is a new shaft or if the cup plug was removed, install the cup plug in the front output shaft, using a suitable driver. Install the cup plug 1 mm (0.039 in) from flush with the end of the shaft.
Install the front output shaft assembly.
Install the input shaft.
Install the drive chain and sprockets. The blue link on the chain faces up.
Install the front sun gear.
With the rear side of the planetary differential facing up, align the marks on the pinion gears. Position the alignment marks with an area on the planetary housing that can be reference for all gears.
Install the planetary differential assembly. Do not rotate the planetary differential pinion gears when installing. Ensure the alignment marks are still in position.
Lubricate the sun gear thrust washer with J 36850: lubricant, or equivalent.
Install the sun gear thrust washer.
Install the rear sun gear. The shoulder side of the gear faces up. Do not rotate the planetary pinion gears.
Temporarily install the rear output shaft to the planetary differential and the rear sun gear.
Rotate the rear output shaft three or four revolutions to rotate the planetary differential pinion gears. If properly aligned, the planetary pinion gears will rotate freely, and there will be no binding.
Remove the rear output shaft without disturbing the rear sun gear.
Install the front output shaft rear bearing in the rear case half. Use a hammer and a brass drift only on the outer bearing race. Ensure the bearing is kept square to the bore while installing.
Using a hydraulic press and the J 22912-B: bearing remover, install the rear output shaft bearing. The retaining ring groove on the bearing goes toward the input end or forward. Use a suitable press plate on the end of the rear output shaft. Ensure the bearing is supported on the inner race.
Install a NEW retaining ring for the rear output shaft bearing.
Using the J 42176: driver handle (1) and the J 45757: bushing and bearing installer (2), install the input shaft rear support bushing in the rear output shaft.
Install the rear output shaft in the rear case half. Spread the rear output shaft rear bearing outer retaining ring. Install, until the rear output shaft bearing outer retaining ring is seated in the bearing groove.
Install the locating pins in the front case and rear case half, if necessary.
Apply a 3.175 mm (1/8 in) bead of room temperature vulcanizing (RTV) sealant GM P/N 12345739 (Canadian P/N 10953541), or equivalent, to the mating surfaces of the front case half.
Lower the rear case half into place. The rear output may require rotating to align the teeth with the planetary carrier.
Inspect the nylon coating on the case bolts for cuts or tears.
Replace the case bolts if there is any damage to the nylon coating.
Install the case bolts, the washers, and the brackets.
Tighten the case bolts to 21 N.m (15 lb ft).
Using J 45380: bushing remover and installer, install the output shaft bushing, if removed or new.
Using J 45756: seal installer, install the rear output shaft seal.
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
Install the drain plug and the fill plug.
Tighten the drain plug and fill plug to 25 N.m (18 lb ft).
Using the J 43484: seal installer (2) and the J 8092: driver (1), install the front output shaft seal.
Using the J 42738: seal installer, install the front input shaft seal.
Remove the transfer case from the J 45759: assembly fixture.

Transfer Case Description and Operation

The Borg Warner (BW) model 4485, RPO NR3 transfer case is a 1-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 2 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

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

The BW 4485 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 4485 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®VI Automatic Transmission Fluid (ATF) GM P/N 88861003 (Canadian P/N 88861004), which is red in color.

Scheme 3

Scheme 3: Power Flow

When the BW 4485 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.

Special Tools

Illustration Tool Number/Description J 2619-01 Slide Hammer J 3289-20 Holding Fixture J 8092 Driver Handle J 22912-01 Rear Pinion and Axle Bearing Remover J 23907 Slide Hammer with Bearing Adapter J 26941 Bushing and Bearing Remover - 3-4 inch J 36825 Output Shaft Oil Seal Remover (4WD Models Only) J 36850 Transjel Lubricant J 42176 Universal Driver Handle - Non-Threaded J 42738 Seal Installer J 43484 Front Output Shaft Seal Installer J 45124 Removal Bridge J-45124-9 Puller Legs J 45358 Case Spreader J 45380 Transfer Case Rear Bushing Remover and Installer J 45548 Mainshaft Support Bushing/Bearing Remover J 45756 Rear Output Shaft Seal Installer J 45757 Mainshaft Support Bushing and Bearing Installer J 45759 Assembly Fixture