Transfer Case - Overhaul - Bw 4476/79 Cadillac STS I

Fastener Tightening Specifications

Fastener Tightening Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Capacities - Approximate Fluid

Capacities - Approximate Fluid

Scheme 6

Scheme 7

Transfer Case Disassemble

Tools Required

1. DT-47752 Split Plate Set. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
2. J-2619-A Slide Hammer w/Adapter. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
3. J 8107-2 Side Bearing Puller Pilot. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
4. J 8433 Two Jaw Puller. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
5. J 22888-20A Universal Two Jaw Puller. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
6. J 29369-1 Bushing and Bearing Remover. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .

1. Remove the bolts (16) and the dampener (300), some models .
2. Remove the drain plug (8) and the fill plug (6). Ensure all transfer case fluid is drained out of the transfer case.
3. Remove the 17 case attaching bolts (11).
4. Using a screwdriver at the pry points located on the case (1) and cover (2), pry the case (1) and cover (2) apart.
5. Separate the case (1) and cover (2).
6. Remove the alignment dowel (3) from the case, if necessary.
7. Remove the chain snubber.
8. Install 1 plate of the DT-47752 perpendicular to the chain and rotate 180 degrees. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
9. Install the second plate perpendicular to the chain and secure with the short plate bolts.
10. Install the DT-47752-2 (2) onto the front output shaft (112).
11. Using the long bolts and washers from DT-47752 , install the J 8433 (1). See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) . Tighten evenly so the puller remains parallel to the plates.
12. Install DT-47752-3 into the input shaft.
13. Using an impact wrench, tighten the forcing screw of the DT-47752-2 in order to remove the sprockets, chain and carrier assembly.
14. Remove the J 8433 (1) and the DT-47752-2 (2). See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
15. Remove the lower sprocket (112), chain (109) and carrier (111) as an assembly.
16. Remove the DT-47752 from the case. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
17. Remove the snap ring (114).
18. Push the front output shaft (112) from the case (1).
19. Remove the vent baffle bolt (9) and baffle (10) from the case (1).
20. Using a hammer and a suitable driver, remove the front output seal (13) and input seal (14) from the case (1).
21. Using a hammer and a suitable punch, remove the front output bearing (113) and input bearing (117) if they are to be replaced.
22. If required, remove the vent (15) and discard.
23. Replace it with a NEW vent.
24. Remove the thrust washer (100) from the carrier (111).
25. Using a press, remove the input shaft assembly (118, 107 and 110) from the carrier (111).
26. Note the direction of the carrier assembly (111). The groove around the splines for 50/50 and 40/60 ratios face towards the output shaft.
27. Using the J 22888-20A (1) and the J 8107-2 (2), remove the sun gear (101) from the rear output shaft. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
28. Using snap ring pliers, remove the snap ring (102) from the output shaft (106).
29. Push the output shaft (106) from the cover (2).
30. Using a hammer and a suitable punch, from inside the cover, drive out the rear output seal (7) and the outside output bearing (104).
31. Using a hammer and a suitable punch, from outside the cover (2), inside the output shaft bore, drive out the inner output shaft bearing (103).
32. Using the J-2619-A (1) and the J 29369-1 (2), remove the front output cover bearing (116) from the cover. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .

Cleaning and Inspection

Tools Required

1. J-2619-A Slide Hammer w/Adapter. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
2. J 3289-20 Holding Fixture
3. J 45548 Mainshaft Support Bushing/Bearing Remover. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
4. J 46266 Bushing Installer. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .

1. Clean the front case half in cleaning solvent and air dry.
2. Remove the sealer from the case sealing surfaces (2).
3. Inspect the case for being broken or cracked.
4. Inspect the front output shaft front bearing bore (4) for the following conditions: A spun bearing Cracks
5. Inspect the input shaft bearing bore (3) for the following conditions: A spun bearing Cracks
6. Replace the front case half if any of the above conditions are found.
7. Inspect the sealing surfaces (2) for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the front case to transmission case mounting surface for damage.
10. Inspect the front output shaft front bearing and the input shaft bearing for the following conditions: Roughness Brinelling Pitting
11. Replace the bearings if any of the above conditions are found. Refer to «Transfer Case Disassemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-assemble) .

Cover

1. Clean the cover in cleaning solvent and air dry.
2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Replace the case if it is broken or cracked.
5. Inspect the sealing surfaces (1) for damage.
6. Repair small scratches or nicks with a soft stone.
7. Inspect the case threaded bolt holes (2) for damage.
8. Repair any damaged threads.
9. Inspect the front output shaft rear bearing bore (3) for the following conditions: Spun bearing Cracks
10. Inspect the rear output shaft rear bearing bore (4) for the following conditions: Spun bearing Cracks
11. Replace the case if the bearing has spun. Refer to «Transfer Case Disassemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-assemble) .

Differential Components

1. Clean the planetary differential in cleaning solvent. Do not disassemble the planetary differential.
2. 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.
3. Inspect the pinion gears for the following conditions: Chipped teeth Debris embedded in the root of the teeth Excessive side movement from worn bushings or shafts
4. Inspect the planetary housing for cracks at the web (1) of the housing.
5. Inspect the thrust washer surface (2) for scoring or excessive wear.
6. Inspect the planetary housing for distortion.
7. Inspect the planetary housing to mainshaft splines for excessive wear.
8. Replace the planetary differential if any of the above conditions are found.
9. Inspect the planetary thrust washers for excessive wear or scoring.
10. Replace the thrust washers if they are faulty.

1. Clean the front sun gear (110) and the rear sun gear (101) in cleaning solvent and air dry.
2. Inspect the teeth on the front sun gear (110) and the rear sun gear (101) for the following conditions: Chipped teeth Excessively worn gear surfaces Slight wear marks are normal. Debris embedded in the root of the teeth
3. Inspect the thrust washer surfaces for excessive wear or scoring.
4. Replace the front sun gear (110) and the rear sun gear (101) if they are faulty.

Drive Chain and Sprockets

1. Clean the drive chain (109), drive sprocket (107), snubber (3) and driven sprocket (115) in cleaning solvent and air dry.
2. Inspect the drive chain (109) for the following conditions: Loose link pins Binding or stiff links Debris embedded in the links Worn teeth surfaces
3. Replace the chain if any of the above conditions are found.
4. Inspect the driven sprocket (115) and the drive sprocket (107) for the following conditions: Chipped teeth Excessively worn gear surfaces Slight wear marks are normal. Debris embedded in the root of the teeth
5. Inspect the drive sprocket (107) and bushing (105) for the following conditions: Excessive wear Scoring
6. Replace the sprockets if any of the above conditions are found. The chain and sprockets may be replaced separately.
7. Inspect the snubber (3) for an excessively worn or gouged lining. Slight wear marks are normal.
8. Inspect the chain and sprockets for the cause of the wear. Replace as required.
9. If the bushing in the sprocket (107) is damaged, it can be replaced using the J 46266 and a press to remove the bushing. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
10. Clean the bushing bore with solvent.
11. Inspect the bushing bore for nicks or burrs.
12. Place the NEW bushing (108) in the sprocket bore.
13. Use the other side of the J 46266 and press in the NEW bushing until the tool meets the sprocket. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .

Input Shaft

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

Front Output Shaft

1. Clean the front output shaft (112) in cleaning solvent and air dry.
2. Inspect for spun bearings at the front output shaft bearing areas.
3. Inspect the front output internal splines and driven gear splines for damage or excessive wear.
4. Replace the front output shaft if it is damaged.
5. Inspect the front output shaft bearings (113 and 116) for the following conditions: Scoring Pitting Brinelling Excessive wear
6. Replace the front output shaft bearings if they are faulty. Refer to «Transfer Case Disassemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-assemble) .

Rear Output Shaft

1. Clean the rear output shaft (106) and rear output shaft bearings (104) in cleaning solvent.
2. Air dry and ensure all solvent is removed from the bearing.
3. Inspect the rear output shaft bearings (103 and 104) for the following conditions: Scoring Pitting Brinelling Excessive wear
4. Replace the rear output shaft bearings if they are faulty. Refer to «Transfer Case Disassemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-disassemble) and «Transfer Case Assemble»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__transfer-case-assemble) .
5. Inspect the mainshaft rear support bushing (105) for the following conditions: Pitted Wear Corrosion
6. Replace the rear output shaft if any of the above conditions are found.
7. Inspect the rear output shaft splines for wear or damage.
8. Inspect the rear output shaft bearing area for a spun bearing.
9. If the bearing area or splines are damaged, replace the rear output shaft.
10. If the bushing (105) is damaged, it can be replaced. Place J 45548 inside of the bushing. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
11. With the ridge on the J 45548 , behind the bushing, tighten the center bolt of the J 45548 in order to lock it behind the bushing. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
12. With position pins removed from the J 3289-20 , place the output shaft as shown.
13. Insert the J-2619-A (2) into the J 45548 (1) and pull the bushing from the output shaft. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
14. Clean the bushing bore with solvent. Inspect for nicks and burrs.
15. Place a NEW bushing (105) in the bore.
16. Place the J 46266 into the bushing as shown. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
17. Using a press, push the bushing into the bore until the tool meets the output shaft.

Transfer Case Assemble

Tools Required

1. J 5590 Pinion Bearing Race Installer - Rear
2. J 8092 Driver Handle
3. J 24433 Pinion Cone and Side Bearing Installer. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
4. J 36850 Transjel Lubricant
5. J 46268 Output Seal Installer. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
6. J 46269 Input Seal Installer. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .

1. Install the input shaft bearing (117) into the case (1).
2. Install the front output shaft bearing (113) into the case (1).
3. Using the J 46269 (2) and the J 8092 (1), install the input shaft oil seal (13).
4. Using the J 46268 (2) and the J 8092 (1), install the front output shaft oil seal (14).
5. Install the chain snubber (3).
6. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bolts (4). Tighten: Tighten the bolts to 7 N.m (62 lb in).
7. Install the vent baffle (10).
8. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bolt (9). Tighten: Tighten the bolt to 7 N.m (62 lb in).
9. With the thrust washer side of the planetary differential facing down, align the marks on the pinion gears. Position the alignment marks with an area on the planetary differential that can be reference for all gears.
10. Use a press to install the input shaft assembly to the carrier (111).
11. Lubricate the thrust washer (100) with J 36850 or equivalent.
12. Install the thrust washer over the rear of the input shaft, into the groove of the carrier (111).
13. Insert the sun gear (101) into the carrier.
14. If the pinion gears are properly aligned, the sun gear (101) carrier assembly will rotate freely.
15. Remove the sun gear (101) from the carrier (111).
16. Assemble the front output shaft (112) to the case (1).
17. Assemble the snap ring (114).
18. Assemble the chain (109), upper gear of the planetary assembly, and lower sprocket (115) to the case (1).
19. Use the J 5590 and a press to fully seat the lower sprocket (115) to the front output shaft, while guiding the input shaft of the planetary assembly, until it is seated to the case.
20. Install the rear output shaft bearing (104).
21. Using the J 46268 (2) and the J 8092 (1), install the rear output oil seal (7).
22. Install the inner output shaft bearing (103).
23. Install the front output shaft inner bearing (116).
24. Install the rear output shaft (106) by pushing it in through the bearings.
25. Install the rear output shaft snap ring (102) in the lower groove of the output shaft (106).
26. Use the J 24433 and a press to install the sun gear (101) to the output shaft. See «Special Tools»(/cadillac/sts/i-2004-2007/remont/transfer-case/#transfer-case-overhaul-bw-447679__special-tools) .
27. Install the dowel pins (5) into the cover (2), if necessary.
28. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the cover (2).
29. Insert the dowel pin (3), if removed.
30. Lower the cover (2) over the case (1). Turn the rear output shaft in order to align the splines and the shaft into the bearing in the cover.
31. Install the case bolts (11). Tighten: Tighten the case bolts to 25 N.m (18 lb ft) in a criss-cross pattern.
32. Install the vent breather by pushing it into the hole. Align the flat on vent with the flat on the case.
33. Lightly pull on the vent to ensure proper installation.
34. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the drain plug (8).
35. Install the drain plug (8). Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
36. Fill the transfer case with 1.4 liter (1.5 qt) of DEXRON III® GM P/N 12346143 (Canadian P/N 10952622), or fill to the bottom of fill plug threads. Ensure the vehicle is on a level surface.
37. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fill plug.
38. Install the fill plug (6). Tighten: Tighten the fill plug to 25 N.m (18 lb ft).
39. Install the dampener (300) and the bolts (16). Tighten: Tighten the bolts to 27 N.m (20 lb ft).

Special Tools

Special Tools Illustration Tool Number/Description DT-47752 Split Plate Set J-2619-A Slide Hammer w/Adapter J 3289-20 Holding Fixture J 5590 Pinion Bearing Race Installer - Rear J 8092 Universal Driver Handle J 8107-2 Side Bearing Puller Pilot J 8433 Two Jaw Puller J 22888-20A Universal Two Jaw Puller J 24433 Pinion Cone and Side Bearing Installer J 29369-1 Bushing and Bearing Remover J 36850 Transjel Lubricant J 45548 Mainshaft Support Bushing/Bearing Remover J 46266 Bushing Installer J 46268 Output Seal Installer J 46269 Input Seal Installer

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

See also:
• Special Tools
• Transfer Case Disassemble
• Transfer Case Assemble