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Transfer Case - Aam Cadillac SRX II рестайлинг

Transfer Case 38 illustrations ~4717 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Transfer Case Bracket-to-Engine Bolts22 N.m16 lb ft
Transfer Case Bracket-to-Rear Extension Housing Bolts58 N.m43 lb ft
Transfer Case-to-Transmission Bolts110 N.m81 lb ft
Transfer Case-to-Transmission Bolts- RPO MXE
First pass100 N.m74 lb ft
Second pass60 degrees
Transfer Case Housing-to-Rear Extension Housing Bolts
First pass25 N.m18 lb ft
Second pass130 degrees
Transfer Case Oil Fill Plug40 N.m30 lb ft
Transfer Case Oil Drain Plug40 N.m30 lb ft
Transfer Case Rear Output Shaft Flange Bolts35 N.m25 lb ft
Transfer Case Vent25 N.m18 lb ft

Fastener Tightening Specifications

Approximate Fluid Capacities

ApplicationSpecification
MetricEnglish
Transfer Case Oil GM P/N 19256084 (Canadian P/N 19256085)0.65 L0.69 qt

Approximate Fluid Capacities

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United SatesCanada
Transfer Case OilLubricant1925608419256085
Intermediate Shaft Output SplinesLubricant105134400993037
Transfer Case Rear Extension Housing BoltsThreadlocker8902129710953488
Transfer Case Rear Extension Housing Bolt HolesCleaner8886265088901247
Vent Hose Connector ThreadsSealant1234600410953480

Adhesives, Fluids, Lubricants, and Sealers

Scheme 1

Scheme 1: Transfer Case Components
Scheme 1: Transfer Case Components
CalloutComponent Name
1Transmission-to-Transfer Case O-ring Seal
2Input Shaft Front (outer) Seal
3Transfer Case Vent Hose Connector
4Transfer Case Housing
5Transfer Case Rear Extension Housing-to-Transfer Case Seal
6Transfer Case Vent Baffle
7Input Shaft Front (inner) Seal
8Input Shaft Front Bearing Race
9Input Shaft Front Bearing
10Input Shaft
11Transfer Case Vent Baffle Bolt
12Idler Shaft Front Bearing
13Idler Shaft Front Bearing Race
14Idler Shaft Front Bearing Shim
15Input Shaft Rear Bearing
16Input Shaft Rear Bearing Race
17Input Shaft Rear Bearing Shim
18Input Shaft Bearing Retainer Rear Seal
19Rear Extension Housing
20Transfer Case-to-Rear Extension Housing Bolt
21Intermediate Shaft Seal
22Transfer Case Fill Plug
23Transfer Case Fill Plug Sealing Washer
24Transfer Case-to-Rear Extension Housing Locating Pin
25Idler Shaft Rear Bearing Shim
26Idler Shaft Rear Bearing Race
27Idler Shaft Rear Bearing
28Idler Shaft
29Transfer Case Seal
30Intermediate Shaft O-ring Seal - Second Design
31Intermediate Shaft Dirt Deflector - Model Dependent
32Intermediate Shaft Assembly Retaining Ring
33Intermediate Shaft Bearing Retaining Ring
34Intermediate Shaft Bearing
35Intermediate Shaft
36Rear Output Shaft Housing O-ring Seal
37Rear Output Shaft Shim
38Rear Output Shaft
39Rear Output Shaft Bearing
40Rear Output Shaft Bearing Race
41Rear Output Shaft Housing
42Rear Output Shaft Bearing Spacer
43Rear Output Shaft Bearing Race
44Rear Output Shaft Bearing
45Rear Output Drive Gear Nut
46Rear Output Shaft Seal
47Rear Output Shaft Housing Bolt
48Transfer Case Drain Plug
49Transfer Case Drain Plug Sealing Washer

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: Transfer Case Mounting
Scheme 3: Transfer Case Mounting
CalloutComponent Name
1Transaxle Brace
2Transaxle Brace Bolt
3Transfer Case Bracket-to-Engine Bolt
4Transfer Case Bracket Bolt
5Transfer Case Bracket
6Transfer Case
7Transfer Case-to-Transmission Bolt
8Transaxle Brace-to-Engine Bolt

Scheme 4

Scheme 4: Vent Hose Assembly
Scheme 4: Vent Hose Assembly
CalloutComponent Name
1Vent Hose Assembly
2Strap
3Bolt

Strategy Based Diagnostics

Review the system operations in order to familiarize yourself with the system functions. Refer to Transfer Case Disassembled View , Transfer Case Description and Operation , and Rear Drive Axle Description and Operation . All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis .

Visual/Physical Inspection

  1. Inspect for aftermarket devices, which could affect the operation of the vehicle. Refer to «Checking Aftermarket Accessories»(/cadillac/srx/ii-2012-2016/remont/body-electrical/#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»(/cadillac/srx/ii-2012-2016/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures)
  2. «Noisy in Drive»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__noisy-in-drive)
  3. «Noisy When Coasting»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__noisy-when-coasting)
  4. «Intermittent Noise»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__intermittent-noise)
  5. «Constant Noise»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__constant-noise)
  6. «Transfer Case Leak Diagnosis»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__transfer-case-leak-diagnosis)

Noisy in Drive

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis.
Low gear oil levelInspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers .
Incorrect gear oil in the transfer caseReplace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Water or contamination within the 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 or noisy wheel bearingsReplace the wheel bearings as required.
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.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.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 hose assemblyReplace the ventilation hose assembly, as required.
Leaking at the transfer case left side weep hole A transmission oil leak at the transfer case weep hole area is caused by the transmission right side drive shaft seal. A gear oil leak at the transfer case weep hole area is caused by the transfer case input shaft front (inner) seal.Replace components as required. If the leak is transmission or O-ring related, do not replace the transfer case input shaft seals.
Leaking at the transfer case right side weep hole A transmission or gear oil leak at the transfer case right side weep hole is caused by the input shaft seal located in the rear extension housing.Replace the input shaft seal.
Leaking ATF at the right side axle shaft-to-intermediate shaft bearing locationReplace the intermediate shaft seal located in the rear extension housing.
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 the rear output shaft seal as required. The O-ring is not serviceable on AAM transfer case.
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. A transmission oil leak at the transfer case weep hole area is caused by the transmission right side drive shaft seal. A gear oil leak at the transfer case weep hole area is caused by the transfer case input shaft front (inner) seal.NOTE: If the leak is transmission or O-ring related, do not replace the transfer case input shaft seals. Identify the type of oil leak. Replace components as required.
Case half seam leak AAMDisassemble and replace the transfer case-to-rear extension housing O-ring seal.
Leaking through caseInspect for a cracked case. Inspect for case porosity.
CAUTION
Do not clean using brake cleaner or other reactive solvents as these solvents can damage rubber gaskets, seals and bushings.
NOTE
Do not drive the vehicle on the freeway as this will splatter oil inhibiting leak diagnosis.
NOTE
If the leak is transmission or O-ring related, do not replace the transfer case input shaft seals.

Transfer Case Leak Diagnosis

Removal Procedure

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/srx/ii-2012-2016/remont/hoistjack/#general-information) .
  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 40 (30 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 40 (30 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/srx/ii-2012-2016/remont/hoistjack/#general-information) .
  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 40 (30 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 40 (30 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/srx/ii-2012-2016/remont/hoistjack/#general-information) .
  2. Remove and DISCARD the fill plug (1) and seal.
  1. Install a NEW fill plug (1) and seal and tighten to 40 (30 lb ft).
  2. Lower the vehicle.

Special Tools

  1. DT-50768 Seal Installer
  2. J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools .

  1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  2. Remove the dirt deflector (1). 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.
  3. Discard the seal assembly.
  1. Install the front wheel drive intermediate shaft dirt deflector (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
  2. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  1. DT-113-2-A Holder
  2. DT-622-A Transmission Bracket
  3. DT-48076 Bearing Installer
  4. DT-49104 Protective Collar
  5. DT-50768 Seal Installer
  6. J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools .

  1. Remove the transfer case from the vehicle. Refer to «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Secure the transfer case (3) in DT-113-2-A holder (1), using the DT-622-A bracket (2).
  3. Remove the dirt deflector (1). 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.
  4. Discard the seal assembly.
  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»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  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. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  6. Install the front wheel drive intermediate shaft dirt deflector (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
  7. Install the transfer case in the vehicle. refer to «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. DT-305 Remover/Installer
  2. DT-49954-A Seal Installer

For equivalent regional special tools, refer to Special Tools .

  1. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/cadillac/srx/ii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  2. Remove the inner metal sleeve (1) from the seal by working a screwdriver around the perimeter of the sleeve, prying only against the flat bosses of the output shaft housing.
  3. Remove the rear output shaft seal (1) by working a sharpened chisel around the perimeter of the seal, prying only against the flat bosses of the output shaft housing.
  4. Ensure the seal tension spring (2) is removed from the bore.

Scheme 5

Scheme 5: Installation Procedure
Scheme 5: Installation Procedure
  1. Install the rear output shaft seal (3), using the DT-49954-A installer (2) and DT-305 remover/installer (1).
  2. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/cadillac/srx/ii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  1. DT-50768 Seal Installer
  2. J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools .

  1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  2. Remove the dirt deflector (1). 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.
  3. Discard the seal assembly.
  1. Install the front wheel drive intermediate shaft dirt deflector (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
  2. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  2. Remove the intermediate shaft O-ring (3), as required.
  1. Install the intermediate shaft O-ring (3), as required.
  2. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  1. DT-113-2-A Holder
  2. DT-622-A Transmission Bracket
  3. DT-48076 Bearing Installer
  4. DT-49104 Protective Collar
  5. DT-50768 Seal Installer
  6. J-8092 Driver Handle

For equivalent regional tools, refer to Special Tools .

  1. Remove the transfer case from the vehicle. refer to «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  2. Secure the transfer case (3) in DT-113-2-A holder (1), using the DT-622-A bracket (2).
  3. Remove the dirt deflector (1). 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.
  4. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  5. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.
  6. Remove the bearing. Refer to front wheel drive intermediate shaft in «Transfer Case Disassemble»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Install the bearing. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  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. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  5. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  6. Install the front wheel drive intermediate shaft dirt deflector (1) using the DT-50768 seal installer (2) and J-8092 driver handle (3).
  7. Install the transfer case in the vehicle. refer to «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  1. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/cadillac/srx/ii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  2. Drain the oil from the transmission . Refer to «Transmission Fluid Drain and Fill»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) .
  3. Remove the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  4. Remove the transmission rear mount bracket. Refer to «Transmission Rear Mount Replacement (FWD)»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) , «Transmission Rear Mount Replacement (AWD)»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) .
  5. Remove the front catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (Front)»(/cadillac/srx/ii-2012-2016/remont/exhaust/#engine-exhaust-system) , and «Catalytic Converter Replacement - Right Side (Rear)»(/cadillac/srx/ii-2012-2016/remont/exhaust/#engine-exhaust-system) .
  6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).
  7. Remove the transfer case bracket-to-transfer case bolts (2, 4).
  8. Remove the transfer case bracket-to-engine bolts (3, 8).
  9. Remove the brackets (1, 5).
  10. Support the transfer case (6) with a suitable jack, and secure with suitable straps.
  11. Remove the remaining transfer case-to-transmission bolts (2).
  12. Separate the transfer case (1) from the transmission and remove the transfer case.
  13. Remove and discard the transfer case-to-transmission O-ring.
  1. Clean the contact surfaces between the transfer case and the transmission.
  2. Install a new transfer case-to-transmission O-ring (1).
  3. Support the transfer case with a suitable jack, and secure with suitable straps.
  4. Raise and align the transfer case in the correct position in relation to the transmission.
  5. Install the transfer case (1) to the transmission.
  6. Install the transfer case-to-transmission bolts (2) and tighten to 110 N.m (81 lb ft).
  7. Install the brackets (1, 5).
  8. Install the transfer case bracket-to-transfer case bolts (2, 4)
  9. Loosely install the transfer case bracket-to-engine bolt (3)
  10. Tighten the bracket-to-transfer case bolts (2, 4) first time to 5 N.m (44 lb in).
  11. Tighten the bracket-to-engine bolt (3) to 22 N.m (16 lb ft).
  12. Tighten the bracket-to-transfer case bolts (2, 4 8) to 58 N.m (42 lb ft).
  13. Install the transmission rear mount bracket. Refer to «Transmission Rear Mount Replacement (FWD)»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) , «Transmission Rear Mount Replacement (AWD)»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) .
  14. Install the transfer case vent hose (2), strap (1), and bolt (3).
  15. Tighten the transfer case vent hose bolt, to 22 N.m (17 lb ft).
  16. Install the front catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (Front)»(/cadillac/srx/ii-2012-2016/remont/exhaust/#engine-exhaust-system) , and «Catalytic Converter Replacement - Right Side (Rear)»(/cadillac/srx/ii-2012-2016/remont/exhaust/#engine-exhaust-system) .
  17. Install the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(/cadillac/srx/ii-2012-2016/remont/axle-shafts/#wheel-drive-shafts) .
  18. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/cadillac/srx/ii-2012-2016/remont/driveshaft-universal-joints/#propeller-shaft) .
  19. Fill the transmission with oil. Refer to «Transmission Fluid Drain and Fill»(/cadillac/srx/ii-2012-2016/remont/automatic-trans/#automatic-transmission-6t70-m7u-m7w-repair-instructions-on-vehicle) .
  20. Fill with transfer case oil. Refer to «Approximate Fluid Capacities»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__approximate-fluid-capacities) .
  1. Remove the transfer case from the vehicle. refer to «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .
  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 «Transfer Case Replacement (M7U)»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam) .

Scheme 6

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

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

Scheme 7

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

Remove and discard the oil fill plug (1) and seal.

Scheme 8

Scheme 8: Transfer Case Vent Removal
Scheme 8: Transfer Case Vent Removal

Remove the transfer case vent hose connector (1), as required.

Scheme 9

Scheme 9: Transfer Case-to-Transmission Seal Removal
Scheme 9: Transfer Case-to-Transmission Seal Removal

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

Scheme 10

Scheme 10: Locating Bushing Removal
Scheme 10: Locating Bushing Removal

Remove the transfer case locating bushing (1), using multi-grip pliers as required - Model Dependent.

Front Wheel Drive Intermediate Shaft Removal

Special Tools

  1. DT-113-2-A Holder
  2. DT-622-A Transmission Bracket

For equivalent regional tools, refer to Special Tools .

  1. Secure the transfer case (3) in DT-113-2-A holder (1) , using the DT-622-A bracket (2) .
  2. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the 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.
  4. Discard the seal assembly (1).
  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.

Front Wheel Drive Intermediate Shaft Bearing Removal

Special Tools

DT-307-B Remover Plate

For equivalent regional tools, refer to Special Tools .

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

Rear Output Shaft Seal Removal

  1. Remove the inner metal sleeve (1) from the seal by working a screwdriver around the perimeter of the sleeve, prying only against the flat bosses of the output shaft housing.
  2. Remove the rear output shaft seal (1) by working a sharpened chisel around the perimeter of the seal, prying only against the flat bosses of the output shaft housing.
  3. Ensure the seal tension spring (2) is removed from the bore.

Rear Output Shaft Housing Removal

The rear output shaft seal (3) is a serviceable component. Refer to Rear Output Shaft Seal Removal and Rear Output Shaft Seal Installation.

Rear Extension Housing Removal

  1. Remove the transfer case rear extension housing bolts (1) from the rear extension housing (2).
  2. Remove the rear extension housing (2) and bolts (3).
  3. Remove and discard the rear extension housing-to-transfer case seal (1).

Input Shaft and Idler Shaft Removal

  1. Remove the input shaft (3)
  2. Remove the idler gear (2).
  3. Remove the idler gear shaft (1) - Model Dependent.

Input Shaft Bearing Retainer Front 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.

Scheme 11

Scheme 11: Idler Gear Shaft Front Seal Removal
Scheme 11: Idler Gear Shaft Front Seal Removal

Remove the transfer case idler gear shaft front seal (1) from transfer case - Model Dependent.

Scheme 12

Scheme 12: Idler Gear Shaft Rear Seal Removal
Scheme 12: Idler Gear Shaft Rear Seal Removal

Remove the transfer case idler gear shaft rear seal (1) from the rear extension housing - Model Dependent.

Scheme 13

Scheme 13: Input Shaft Bearing Retainer Rear Seal Removal
Scheme 13: Input Shaft Bearing Retainer Rear Seal Removal

Note. To avoid damage to the housing, use a brass punch to remove the seal.

Remove the transfer case input shaft rear seal (1) from the rear extension housing.

Scheme 14

Scheme 14: Front Wheel Drive Intermediate Shaft Seal Removal
Scheme 14: Front Wheel Drive Intermediate Shaft Seal Removal

Remove the intermediate shaft seal (1) from the rear extension housing using a suitable screw driver.

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: Damages 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 other damage.
  4. Inspect the input shaft gear teeth (4) for excessive wear or damage.

Idler Gear and Idler Shaft

  1. Clean the idler shaft in cleaning solvent.
  2. Inspect the idler shaft seal surfaces (8) for excessive grooves, rust, pitting or other damage. - Model Dependent
  3. Inspect the sealing surfaces of the idler gear shaft (5) for excessive grooves, rust, pitting or other damage. - Model Dependent
  4. Inspect the idler shaft gear teeth (3 and 4) for excessive wear or damage
  5. Inspect the bearings (2 and 6) for pitting, wear or other damage.
  1. DT-305-1/KM-305-1 Remover/Installer
  2. DT-49953 Seal Installer

For equivalent regional tools, refer to Special Tools .

Scheme 15

Scheme 15: Front Wheel Drive Intermediate Shaft Seal Installation
Scheme 15: Front Wheel Drive Intermediate Shaft Seal Installation

Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 installer (2) with DT-305-1/KM-305-1 remover/installer (1) .

Input Shaft Bearing Retainer Rear Seal Installation

Special Tools

  1. DT-305-1/KM-305-1 Remover/Installer
  2. DT-49951 Seal Installer

For equivalent regional tools, refer to Special Tools

  1. Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to clean the threads of old threadlocking material.
  2. Spray thread cleaner into the holes. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  3. Clean the transfer case housing and rear extension housing bolt holes with compressed air.
  4. Install the NEW input shaft rear seal (1) to the rear extension housing using the DT-49951 installer (2) and DT-305-1/KM-305-1 remover/installer (3).

Idler Gear Shaft Rear Seal Installation

Install a NEW idler gear shaft rear seal (1) to the rear extension housing - Model Dependent.

Idler Gear Shaft Front Seal Installation

Install a NEW transfer case idler gear shaft front seal (1) to transfer case - Model Dependent.

Input Shaft Bearing Retainer Front Seals Installation

Special Tools

  1. DT-305-1/KM-305-1 Remover/Installer
  2. DT-49952 Installer

For equivalent regional tools, refer to Special Tools .

  1. Install the input shaft front (inner) seal (1), to the transfer case using the DT-49952 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-49952 installer (2) and DT-305-1/KM-305-1 remover/installer (3) .

Scheme 16

Scheme 16: Input Shaft and Idler Gear Installation
Scheme 16: Input Shaft and Idler Gear Installation
CAUTIONCover the splines of the input shaft to prevent damage to the input shaft oil seals during installation.

Install input shaft (1) and idler gear (2).

Scheme 17

Scheme 17: Rear Extension Housing Installation - Model Dependent
Scheme 17: Rear Extension Housing Installation - Model Dependent
  1. Install the idler gear shaft (1) to the rear extension housing - Model Dependent.
  2. Install a NEW rear extension housing-to-transfer case seal (1).
  3. Install the rear extension housing (1) and idler gear shaft to the transfer case housing. Position the idler gear shaft into the center opening of the idler gear.
  4. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (1). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  5. 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 25 N.m (18 lb ft). Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.

Scheme 18

Scheme 18: Rear Extension Housing Installation - RPO MH4
Scheme 18: Rear Extension Housing Installation - RPO MH4
  1. Install a NEW rear extension housing-to-transfer case seal (1).
  2. Install the rear extension housing onto the transfer case housing .
  3. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  4. 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 25 N.m (18 lb ft). Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 130 degrees.

Rear Output Shaft Seal Installation

Special Tools

  1. DT-305-1/KM-305-1 Remover/Installer
  2. DT-49954-A Seal Installer

For equivalent regional special tools, refer to Special Tools .

Install the rear output shaft seal (3), using the DT-49954-A installer (2) and DT-305-1/KM-305-1 remover/installer (1).

Front Wheel Drive Intermediate Shaft Bearing Installation

Special Tools

DT-48076 Bearing Installer

For equivalent regional tools, refer to Special Tools .

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

Front Wheel Drive Intermediate Shaft Installation

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. 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.
  2. Remove the DT-49104 protective collar (1).
  3. Apply grease to the output splines (1) of the intermediate shaft. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  4. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
  5. Install the dirt deflector (1) using the DT-48076 installer.
  6. 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).

Locating Bushing Installation

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

Transfer Case-to-Transmission Seal Installation

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

Transfer Case Vent Installation

  1. Apply sealant to the threads of the vent hose connector. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/cadillac/srx/ii-2012-2016/remont/transfer-case/#transfer-case-aam__adhesives-fluids-lubricants-and-sealers) .
  2. Install the transfer case vent hose connector (1) and tighten to 25 N.m (18 lb ft).

Oil Drain Plug Installation

CAUTIONRefer to Fastener Caution .

Install a NEW oil drain plug (1) and tighten to 40 N.m (30 lb ft).

Oil Fill Plug Installation

  1. Install a NEW transfer case oil fill plug (1).
  2. Once the transfer case has been filled with oil, tighten the oil fill plug to 40 N.m (30 lb ft).
  3. Remove the transfer case (3) from DT-622-A bracket (2) and DT-113-2-A holder (1) .

Scheme 19

Scheme 19: AAM First Design Label Location
Scheme 19: AAM First Design Label Location

The transfer case identification label (1) is located on the top of the front case half.

Scheme 20

Scheme 20: Bar Code
Scheme 20: Bar Code
CalloutComponent Name
1GM Assigned Component Identification
2Last 4 digits of GM Part Number
3Supplier Identification
4Calendar Year Produced
5Julian Date
6Supplier Serial Number
7GM Part Number

Scheme 21

Scheme 21: AAM Second Design Label Location
Scheme 21: AAM Second Design Label Location

The transfer case identification label (1) is located on the side of the front case half.

Scheme 22

Scheme 22: Bar Code
Scheme 22: Bar Code
CalloutComponent Name
1GM Full Part Number
2Broadcast Code
3Supplier DUNs
4VPPS Code
5Supplier Trace Code

Scheme 23

Scheme 23: Transfer Case Identification
Scheme 23: Transfer Case Identification

The build variation of transfer case can be identified by the assembly part number (1) located on the bottom of the transfer case.

Scheme 24

Scheme 24: General
Scheme 24: General

The transfer case oil drain plug (1) is located at the bottom of the assembly to the right side of the rear output shaft.

Scheme 25

Scheme 25
Scheme 25

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 26

Scheme 26
Scheme 26

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

Scheme 27

Scheme 27
Scheme 27

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 28

Scheme 28: Housing and Cover
Scheme 28: Housing and Cover

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 extension housing to the transfer case housing. The mating surfaces of transfer case housing and rear extension housing are sealed by a press-in-place serviceable seal.

Scheme 29

Scheme 29
Scheme 29

The transfer case assembly is bolted to the transmission with four or five transfer case bolts. 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 30

Scheme 30
Scheme 30

A transfer case vent (1) is located on the top area of the transfer case housing. The vent is mated to a remote vent hose assembly that is routed into the engine compartment. The oil drain plug (2) is magnetic. A mounting bracket retains the output end of the rear extension housing to the engine assembly.

Scheme 31

Scheme 31: Bearings and Races
Scheme 31: Bearings and Races

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. For some models, the transfer case rear extension housing has an opening (4) through which one of the transmission-to-transfer case attaching bolts in accessed.

Scheme 32

Scheme 32: Input Shaft
Scheme 32: 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 (1). 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 a double-lip intermediate shaft seal (5). The intermediate shaft seal (5) 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 33

Scheme 33: Idler Gear
Scheme 33: Idler Gear

The idler gear consists of a helical gear (3) and a hypoid gear (4), has a hollow center, and is driven by the helical gear on the input shaft.

The idler hypoid gear (4) 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 (2 and 5). 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.

For some models, there is an additional idler gear shaft (6) located inside and running through the idler gear. The idler shaft is sealed at each end by O-ring seals (1 and 7) within the transfer case and rear extension housings.

Scheme 34

Scheme 34: Rear Output Shaft Housing
Scheme 34: Rear Output Shaft Housing

The rear output shaft housing assembly includes an output shaft (10), 2 tapered roller bearings (3 and 9), a rear output shaft seal (1), shaft retaining nut (2), housing (7) and housing seal (12).

The hypoid gear of the rear output shaft is mated to the hypoid gear of the idler shaft. A shim (11) maintains the proper gear contact.

The housing is retained to the transfer case by 7 bolts (6). The only serviceable component within the rear output shaft and housing assembly is the rear output shaft seal (1).

The only serviceable component within the rear output shaft and housing assembly is the rear output shaft seal (3).

The seal is a unitized/cassette type design to include inner and outer metal sleeves and internal sealing rings.

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 J-42176 KM-305-1 Driver Handle DT-307 B J-22912-B KM-307-B Remover Plate DT-622-A J-36842 KM-622-A Transmission Bracket DT-48076 Bearing Installer DT-49104 Protective Collar DT-49951 Seal Installer DT-49952 Seal Installer DT-49953 Seal Installer DT-49954-A Seal Installer

Scheme 35

Scheme 35: Special Tools
Scheme 35: Special Tools

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38