Transfer Case - Aam: Removal & Installation Cadillac SRX II facelift

Removal Procedure

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-644691-S41218068962014072300000) .
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»(ref-644691-S41218068962014072300000) .
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»(ref-644691-S41218068962014072300000) .
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.

1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .
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)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .

1. Remove the transfer case from the vehicle. Refer to «Transfer Case Replacement (M7U)»(ref-644780-S12764677962014072300000) .
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»(ref-644780-S31983482582014072300000) .

1. Install the bearing, if removed. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(ref-644780-S39243736732014072300000) .
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»(ref-644780-S07401050392014072300000) .
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)»(ref-644780-S12764677962014072300000) .

1. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-644734-S02075725332014072300000) .
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 1

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»(ref-644734-S02075725332014072300000) .

1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .
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)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .

1. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .
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)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .

1. Remove the transfer case from the vehicle. refer to «Transfer Case Replacement (M7U)»(ref-644780-S12764677962014072300000) .
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»(ref-644780-S31983482582014072300000) .

1. Install the bearing. Refer to front wheel drive intermediate shaft in «Transfer Case Assemble»(ref-644780-S39243736732014072300000) .
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»(ref-644780-S07401050392014072300000) .
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)»(ref-644780-S12764677962014072300000) .

1. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-644734-S02075725332014072300000) .
2. Drain the oil from the transmission . Refer to «Transmission Fluid Drain and Fill»(ref-644720-S03080517412014072300000) .
3. Remove the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .
4. Remove the transmission rear mount bracket. Refer to «Transmission Rear Mount Replacement (FWD)»(ref-644720-S23521334712014072300000) , «Transmission Rear Mount Replacement (AWD)»(ref-644720-S28194328382014072300000) .
5. Remove the front catalytic converters. Refer to «Catalytic Converter Replacement - Left Side (Front)»(ref-644733-S34926705892014072300000) , and «Catalytic Converter Replacement - Right Side (Rear)»(ref-644733-S29139986092014072300000) .
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)»(ref-644720-S23521334712014072300000) , «Transmission Rear Mount Replacement (AWD)»(ref-644720-S28194328382014072300000) .
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)»(ref-644733-S34926705892014072300000) , and «Catalytic Converter Replacement - Right Side (Rear)»(ref-644733-S29139986092014072300000) .
17. Install the right drive shaft. Refer to «Front Wheel Drive Shaft Replacement - Right Side (with MH2/MH4)»(ref-644740-S35355671332014072300000) , «Front Wheel Drive Shaft Replacement - Right Side (with MXE)»(ref-644740-S32844767222014072300000) .
18. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-644734-S02075725332014072300000) .
19. Fill the transmission with oil. Refer to «Transmission Fluid Drain and Fill»(ref-644720-S03080517412014072300000) .
20. Fill with transfer case oil. Refer to «Approximate Fluid Capacities»(ref-644780-S10051059032014072300000) .

1. Remove the transfer case from the vehicle. refer to «Transfer Case Replacement (M7U)»(ref-644780-S12764677962014072300000) .
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)»(ref-644780-S12764677962014072300000) .

Scheme 2

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

Scheme 3

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

Scheme 4

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

Scheme 5

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

Scheme 6

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 7

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

Scheme 8

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

Scheme 9

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 10

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

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»(ref-644780-S07401050392014072300000) .
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 11

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

Scheme 12

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»(ref-644780-S07401050392014072300000) .
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 13

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»(ref-644780-S07401050392014072300000) .
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»(ref-644780-S07401050392014072300000) .
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»(ref-644780-S07401050392014072300000) .
2. Install the transfer case vent hose connector (1) and tighten to 25 N.m (18 lb ft).

Oil Drain Plug Installation

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 14

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

Scheme 15

Scheme 16

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

Scheme 17

Scheme 18

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

Scheme 19

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 20

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 21

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

Scheme 22

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 23

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 24

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 25

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 26

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 27

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 28

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 29

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.