Transfer Case - Tracker: Overhaul Chevrolet Tracker II

Transfer Case Disassemble

Tools Required

1. J 37637-A Case Separator
2. J 8433 Bearing Puller
3. J 37756 Output Shaft Bearing Puller Adapter
4. J 26941 Needle Bearing Puller
5. J 23907 Slide Hammer
6. J 34757 Output Shaft Ring Remover
7. J 39497 Friction Ring Remover and Installer
8. J 22912-01 Split Plate
9. J 34844 Front Shaft Bearing Remover
10. J 28406 Input Gear Bearing Remover
11. J 26900-5 Vernier Caliper

Side View Of Transaxle. Scheme 1

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1. Remove the following components from the rear case: The four-wheel drive switch The steel ball The O-ring
2. Remove the following components from the rear of the case (if equipped): The four-wheel drive low switch and the steel ball The O-ring
3. Remove the following components from the rear case: One bolt The speedometer driven gear case The O-ring
4. Remove the following components from the rear case: The 5 bolts The gearshift bracket The gearshift lever case (1) (Scheme 2): Removing Gearshift Lever Case
5. Remove the following components from the rear case (6): The select return spring bolt (1) The washer (2) The select return spring (3) The select return ball (4) The select return pin (5) (Scheme 3): Removing Components From Rear Case Important: After you remove the rear case, use a magnet in order to extract the pin from the case.
6. Using a standard drift punch and a hammer, drive the roll pin (1) from the reduction shift yoke. This procedure will cause the pin to fall into the transfer case assembly. (Scheme 4): Removing Roll Pin
7. Slide the reduction shift yoke rearward. Pull the reduction shift yoke off the reduction shift shaft and out of the rear case.
8. Remove the 15 rear case bolts. (Scheme 5): Removing Rear Case Bolts
9. Separate the rear case from the center case using a J 37637-A. (Scheme 6): Separating rear case from center case Using a magnet, remove the shift yoke roll pin from inside the rear transfer case.
10. Remove the selective shim from the top of the rear output shaft rear bearing.
11. Use J 34757 in order to remove the following components from the rear output shaft: The speedometer drive gear C-clip The speedometer drive gear (Scheme 7): Removing Speedometer Drive Gear & C-Clip
12. Carefully remove the drive gear ball from the rear output shaft. (Scheme 8): Removing Drive Gear Ball From Rear Output Shaft
13. Use J 34757 in order to remove the rear output shaft rear bearing C-clip from the rear output shaft. (Scheme 9): Removing Rear Output Shaft Rear Bearing C-Clip
14. Use J 8433 with J 37756 in order to remove the rear output shaft rear bearing from the rear output shaft. (Scheme 10): Removing Rear Output Shaft Rear Bearing Important: Do not lose the rear output shaft washer ball underneath the drive sprocket bushing during the sprocket bushing removal.
15. Remove the following components: The drive sprocket bushing (1) output shaft The drive sprocket needle bearing (2) output shaft (Scheme 11): Removing Drive Sprocket Bushing & Drive Sprocket Needle Bearing
16. Remove the following components from the rear output shaft: 2 screws (2) The synchronizing plate (1) (Scheme 12): Removing Synchronizing Plate
17. Remove the following drive components from the rear output shaft and the front output shaft: The drive sprocket (2) The drive chain (1) The rear output shaft washer ball (Scheme 13): Removing Drive Sprocket & Chain
18. Use J 26941 with J 23907 in order to remove the rear output shaft oil seal from the rear case. (Scheme 14): Removing Rear Output Shaft Oil Seal
19. Remove the following components from the rear case: One bolt (1) The oil guide (Scheme 15): Removing Oil Guide
20. Use J 26941 and a hammer in order to remove the rear output shaft needle bearing from the rear case. (Scheme 16): Removing Rear Output Shaft Needle Bearing
21. Remove the following components from the front case: One bolt (2) One washer The countershaft case plate (1) (Scheme 17): Removing Countershaft Case Plate
22. Remove the 9 front case bolts (1) from the front case. (Scheme 18): Removing Front Case Bolts
23. Separate the front case from the center case (1).
24. Remove the countershaft assembly (3) from the center case. (Scheme 19): Separating Front Case From Center Case Important: Do not lose the countershaft washer balls which come out from between the countershaft (9) and the countershaft washers (1,7).
25. Remove the following components from the countershaft (9): The countershaft washers (1,7) The washer balls (3)
26. Remove the following components from the countershaft: The counter gear (6) The countershaft needle bearings (4,8) The countershaft spacer (5)
27. Inspect the countershaft friction ring for excessive wear or damage. Replace as necessary.
28. Inspect the countershaft O-ring for cuts or other damage. Replace as necessary. (Scheme 20): Identifying Countershaft Components Important: Do NOT remove either the countershaft friction ring (10) or the O-ring (2) unless absolutely necessary. If you remove either one, replace with new components.
29. Remove the countershaft O-ring from the countershaft.
30. Use J 39497 and a press arbor (2) in order to remove the countershaft friction ring (1) from the countershaft (3). (Scheme 21): Removing Countershaft Friction Ring
31. Remove the following components from the center case: The 1 rubber plug (1) The 2 locating screws (4) The 1 washer The 2 locating springs (3) The 2 locating balls (2) (Scheme 22): Removing Components From Center Case Important: Observe the alignment marks on the following components in order to ensure correct alignment during assembly: The caged needle bearing The reduction clutch sleeve and hub The front drive clutch sleeve and hub If no alignment marks are present, scribe new marks on these components.
32. Remove the following components from the rear output shaft, in front of the center case: The reduction shift shaft (2) The reduction shift fork (1) The reduction clutch sleeve (3) (Scheme 23): Removing Reduction Shift Shaft, Reduction Shift Fork & Reduction Clutch Sleeve
33. Remove the following components from the rear output shaft, in the rear of the center case: The front drive shift shaft (4) The front drive shift fork (1) The front drive clutch sleeve (2) The front drive clutch hub (3) (Scheme 24): Removing Front Drive Shift Shaft, Front Drive Shift Fork, Front Drive Clutch Sleeve & Front Drive Clutch Hub
34. Remove the interlock ball (1) from the center case passage. (Scheme 25): Removing Interlock Ball From Center Case Passage
35. Use J 34757 in order to remove the reduction hub C-clip (3) from the rear output shaft.
36. Remove the following components from the rear output shaft. The reduction clutch hub (2) The low output gear The low output gear needle bearing (1) (Scheme 26): Removing Low Output Gear Needle Bearing & Reduction Clutch Hub
37. Use a plastic mallet in order to remove the rear output shaft from the center case. (Scheme 27): Removing Rear Output Shaft From Center Case
38. Use J 22912-01 and a press arbor in order to remove the rear output shaft front bearing from the rear output shaft. (Scheme 28): Removing Rear Output Shaft Front Bearing
39. Using a plastic mallet, remove the front output shaft and the bearings (1) from the center case. (Scheme 29): Removing Front Output Shaft & Bearings
40. Remove the following components from the center case: One bolt (1) The case gutter (Scheme 30): Removing Case Gutter
41. Use J 26941 with J 23907 in order to remove the front output shaft oil seal from the center case. (Scheme 31): Removing Front Output Shaft Oil Seal
42. Using J 26941 and a hammer, remove the front output shaft needle bearing from the center case. (Scheme 32): Removing Front Output Shaft Needle Bearing
43. Use J 22912-01 with J 34844 and a press arbor in order to remove the front output shaft bearings from the front output shaft. (Scheme 33): Removing Front Output Shaft Bearings
44. Loosen the center bearing snap ring within the input gear. You cannot remove this snap ring at this time. (Scheme 34): Loosening Center Bearing Snap Ring Within Input Gear
45. Using a plastic mallet, remove the input gear assembly from the front case. (Scheme 35): Removing Input Gear Assembly
46. Using J 26941 with J 23907, remove the input gear oil seal from the front case. (Scheme 36): Removing Input Gear Oil Seal Important: During gear assembly removal, the bearing may move, binding the snap ring in its groove. Apply light pressure with the mallet in order to slide the bearing back to its original position before you attempt to remove the snap ring.
47. Using snap ring pliers, remove the side bearing snap ring (1) from the input gear. (Scheme 37): Removing Side Bearing Snap Ring
48. Use J 22912-01 with J 28406 and a press arbor in order to remove the input gear bearing from the input gear. (Scheme 38): Removing Input Gear Bearing
49. Remove the center bearing snap ring from the input gear.
50. Remove one roll pin from the reduction shift fork.
51. Remove the reduction roll fork from the reduction shift shaft.
52. Remove the following components from the front drive shift shaft: The two E-clips (6) The shaft stop washer (5) The front drive shift fork (4) The front drive fork spring (3) (Scheme 39): Disassembling Front Drive Shift Shaft Important: Careful cleaning of the component mating surfaces will ensure proper case sealing.
53. Clean the following components with solvent and dry thoroughly: The front case The rear case The center case
54. Clean all of the internal components with solvent and dry thoroughly.
55. Inspect the following components for cracks or porosity: The front case The rear case The center case The gearshift lever case Replace as necessary.
56. Inspect the drive teeth and the clutching teeth of all of the gears and sprockets for the following conditions: Broken teeth Chipped teeth Gear clash damage
57. Inspect the shift shafts and the forks for the following conditions: Excessive wear Distortion Replace as necessary
58. Inspect each ball bearing for smooth rotation. If the rotation is abnormal, replace the ball bearing.
59. Inspect the needle bearing and the bearing contacting surface for damage. Replace as required.
60. Inspect the gear tooth surface and the shift mechanism. Correct an abnormal mechanism or replace as required.
61. Inspect the drive chain and the sprockets for abnormal wear or damage. Replace as required.
62. Inspect the oil seal for leakage and inspect the oil seal lip for excessive hardness. Inspect the corresponding surface of the shaft where the oil seal lip contacts. Correct an abnormal condition or replace as required.
63. Inspect the gear tooth surface of the speedometer drive gear. Replace a damaged gear.
64. Inspect the clutch hubs (1) and the sleeves (2) for the following conditions: Poor fit Cracked teeth (3) Broken teeth Replace as necessary (Scheme 40): Inspecting Clutch Hubs & Sleeves
65. Inspect the locating springs for the following conditions: Weakness Distortion Replace as necessary
66. Use J 26900-5 in order to measure each locating spring. Measurement Standard spring length is 19.5 mm (0.768 in). If a spring length measures below 18.0 mm (0.709 in), replace the springs as necessary. (Scheme 41): Measuring Locating Springs
67. Use a feeler gage in order to measure the shift fork-to-clutch sleeve clearance. Measurement The maximum shift fork-to-clutch sleeve clearance is 1.0 mm (0.039 in). If the clearance is greater than 1.0 mm (0.039 in), replace the shift fork and the clutch sleeve as necessary. (Scheme 42): Measuring Shift Fork-To-Clutch Sleeve Clearance
68. Assemble the following components: The synchronizer outer ring (4) The inner ring (2) The cone (3) (Scheme 43): Assembling Synchronizer Outer Ring, Inner Ring & Cone
69. Measure the step difference (1) between the outer ring and the inner ring. Measurement The standard difference between the inner ring and the outer ring is 1.0-1.4 mm (0.039-0.055 in).
70. Measure the key slot width (2) in the synchronizer outer ring (1) and inspect each chamfered tooth of the gear and the synchronizer ring. If necessary, replace the outer ring. Measurement The maximum slot width in the outer ring is 10.1 mm (0.397 in). (Scheme 44): Measuring Key Slot Width In Synchronizer Outer Ring

Transfer Case Assemble

Tools Required

1. J 6133-01 Input Gear Bearing Installer
2. J 37752 Oil Seal Installer
3. J 35871 Input Gear Installer
4. J 35664 Press Tube/Bearing Installer
5. J 22912-01 Split Plate
6. J 37757 Needle Bearing Installer
7. J 37753 Bearing Installer
8. J 36183 Output Rear Shaft Installer
9. J 39497 Friction Ring Remover and Installer
10. J 37751 Oil Seal Installer
11. J 36850 Transjel Transmission Assembly Lubricant
12. J 26900-5 Vernier Caliper

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1. Place the following components onto the front drive shift shaft: The front drive shift shaft C-clip (6) The shaft stop washer (5) The front drive shift fork spring (3) The front drive shift fork (4) The shaft stop washer (Scheme 45): Assembling Front Drive Shift Shaft
2. Tighten the front drive shift shaft C-clip in order to secure the above components to the front drive shift shaft.
3. Install the reduction shift fork onto the reduction shift shaft.
4. Install the reduction shift fork roll pin. This will secure the reduction shift fork to the reduction shift shaft.
5. Use J 6133-01 and a press arbor in order to install the input gear bearing onto the input gear.
6. Install the input gear snap ring onto the input gear. (Scheme 46): Installing Input Gear Bearing & Snap Ring
7. Use J 37752 in order to install the input gear oil seal into the front case. (Scheme 47): Installing Input Gear Oil Seal
8. Apply Loctite® 414 GM P/N 12345493 or equivalent to the threaded portion of the oil guide bolt.
9. Install the oil guide in the rear case. Secure the oil guide with one bolt. Tighten Tighten the oil guide bolt to the 10 N.m (89 in lbs).
10. Use J 35871 and a press arbor in order to install the input gear into the front case. (Scheme 48): Installing Input Gear Into Front Case
11. Install the input gear bearing C-clip onto the input gear.
12. Use J 35664 with J 22912-01 and a press arbor in order to install the front output shaft bearings onto the front output shaft. (Scheme 49): Installing Front Output Shaft Bearings
13. Use J 37757 in order to install the front output shaft needle bearing into the center case. (Scheme 50): Installing Front Output Shaft Needle Bearing
14. Use J 37751 in order to install the front output shaft oil seal into the center case. (Scheme 51): Installing Front Output Shaft Oil Seal
15. Install the case gutters into the center case. Secure one case gutter with a bolt, and secure the other gutter with a screw. Tighten Tighten the case gutter bolt to 12 N.m (106 in lbs).
16. Use a plastic mallet in order to install the front output shaft into the center case.
17. Use J 37753 with J 35664 and a press arbor in order to install the rear output shaft front bearing onto the rear output shaft. (Scheme 52): Installing Rear Output Shaft Front Bearing
18. Install the following components onto the rear output shaft (1): 18.1. The front bearing (2) 18.2. The low output gear needle bearing (3) 18.3. The low output gear (4) 18.4. The reduction clutch hub (5) 18.5. The snap ring (6) (Scheme 53): Assembling Rear Output Shaft
19. Use J 36183 in order to install the rear output shaft into the center case. (Scheme 54): Installing Rear Output Shaft
20. Apply J 36850 to the low output gear needle bearing. Important: Do NOT press-fit the bearing further than the limit line. If you press the bearing all the way down to the case bottom, removal of the bearing will be very difficult.
21. Using a press and J 37753, press-fit the needle bearing into the center case (1). Apply a straightedge (2) to the top surface of the case and press-fit until the limit line (4) of J 37753 aligns with the bottom surface of the straightedge.
22. Install the reduction hub C-clip (3) onto the rear output shaft.
23. Install the caged needle bearing. (Scheme 55): Press-Fitting Needle Bearing Into Center Case
24. Install the interlock ball (1) into the center case passage. Push against the interlock notch of the front drive shift shaft (2). (Scheme 56): Installing Interlock Ball Important: During installation, place the front drive shift shaft at the 4WD position.
25. Install the following components onto the rear output shaft, in the rear of the center case: The front drive shift shaft (4) The front drive shift fork (1) The front drive clutch sleeve (2) The front drive clutch hub (3)
26. Align the marks on the front drive clutch hub and the sleeve. (Scheme 57): Installing Components Onto Rear Output Shaft In Rear Of Center Case Important: During installation, place the reduction shift shaft at the 4WD position.
27. Install the following components onto the rear output shaft, in the front of the center case. The reduction shift shaft (2) The reduction shift fork (1) The reduction clutch sleeve (3)
28. Align the marks on the reduction clutch hub and the sleeve.
29. Apply Loctite® 599 RTV silicone sealer or equivalent to the rubber plug.
30. Apply a light coat of Loctite® pipe sealant GM P/N 1052080 or the equivalent to the threaded portion of the 2 locating screws. (Scheme 58): Installing Components Onto Rear Output Shaft In Front Of Center Case
31. Install the following components into the center case: The 2 locating balls (2) The 2 locating springs (3) The 1 rubber plug (1) The 1 washer The 2 locating screws (4) Tighten Tighten the locating screws to 26 N.m (19 ft lbs). (Scheme 59): Installing Components Into Center Case
32. Install the following components to the countershaft (4): The countershaft spacer (6) The countershaft needle bearings (5) The counter gear (1) The countershaft washer balls (3) The washers (2) (Scheme 60): Assembling Countershaft
33. Install the countershaft assembly (1) into the center case.
34. Apply Loctite® 599 RTV silicone sealer or equivalent to the following surfaces: The front case The center case mating surfaces (Scheme 61): Installing Countershaft Into Center Case
35. Install the front case to the center case. Secure the front case with 9 bolts (1). Tighten Tighten the front case bolts to 23 N.m (17 ft lbs).
36. Apply Loctite® 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft plate bolt. (Scheme 62): Installing Front Case To Center Case
37. Install the countershaft case plate to the front case. Secure the countershaft case plate with 1 bolt (2). Tighten Tighten the countershaft case plate bolt to 23 N.m (17 ft lbs). (Scheme 63): Identifying Countershaft Case Plate Bolt
38. Use J 37757 in order to install the rear output shaft needle bearing in the rear case. (Scheme 64): Installing Rear Output Shaft Needle Bearing
39. Use J 37751 in order to install the rear output shaft oil seal into the rear case.
40. Apply J 36850 to the shaft ball in order to retain it in place on the rear output shaft. (Scheme 65): Installing Rear Output Shaft Oil Seal
41. Install the following components onto the rear output shaft (1) and onto the front output shaft: The rear output shaft washer ball The drive sprocket (3) The drive chain (2) (Scheme 66): Installing Drive Sprocket & Chain
42. Install the synchronizer plate (1) to the front output shaft case. (Scheme 67): Installing Synchronizer Plate
43. Apply Loctite® 414 GM P/N 12345493 or equivalent to the threaded portion of the 2 screws (2). Secure the synchronizer plate with the coated screws.
44. Apply J 36850 to the drive sprocket needle bearing.
45. Install the following components onto the rear output shaft: The drive sprocket needle bearing The drive sprocket bushing
46. Use J 35664 in order to install the rear output shaft rear bearing onto the rear output shaft.
47. Install the rear output shaft rear bearing C-clip onto the rear output shaft.
48. Install the speedometer drive gear on the output rear shaft. Secure the speedometer drive gear with the speedometer drive gear C-clip. (Scheme 68): Installing Rear Output Shaft Rear Bearing
49. Use J 26900-5 and a straightedge in order to measure the rear case bearing bore depth: 49.1. Place the straightedge (1) across the rear case. 49.2. Measure the bearing bore depth (2) including the width of the straightedge. 49.3. Record the measurement. (Scheme 69): Measuring Rear Case Bearing Bore Depth Important: Do NOT press-fit the bearing further than the limit line. If you press the bearing all the way down to the case bottom, removal of the bearing will be very difficult.
50. Using a press and J 37753 (2), press-fit the needle bearing into the rear case (4). Apply a straightedge (3) to the top surface of the case and press-fit until the limit line (1) of J 37753 aligns with the bottom surface of the straightedge. (Scheme 70): Press-Fitting Needle Bearing Into Rear Case
51. Use J 26900-5 and a straightedge in order to measure the height of the rear output shaft rear bearing on the rear output shaft: 51.1. Measure the height of the rear output shaft bearing. Include the width of the straightedge. 51.2. Record the measurement. Important: No shim is needed if the shim clearance is less than 0.13 mm (0.0005 in). (Scheme 71): Measuring Height Of Rear Output Shaft Rear Bearing On Rear Output Shaft
52. Subtract the height of the bearing on the rear output shaft from the rear of the case bearing bore depth in order to find the shim clearance.
53. Apply J 36850 to the selective shim in order to retain it in place on top of the rear output shaft rear bearing.
54. Install the selective shim to the top of the rear output shaft rear bearing.
55. Apply Loctite® 599 RTV silicone sealer or equivalent to the rear case mating surface. (Scheme 72): Inspecting Rear Case Mating Surfaces
56. Install the rear case to the center case. Secure the rear case with 15 bolts. Tighten Tighten the rear case bolts to 23 N.m (17 ft lbs). (Scheme 73): Installing Rear Case To Center Case
57. Install the reduction shift yoke (1) onto the reduction shift shaft in the rear case. (Scheme 74): Installing Reduction Shift Yoke Onto Reduction Shift Shaft
58. Use the reduction shift yoke roll pin in order to secure the reduction shift yoke to the reduction shift shaft.
59. Apply a light coat of Loctite® pipe sealant GM P/N 1052080 or equivalent to the threaded portion of the select return spring bolt.
60. Install the following components into the rear case: The select return pin The select return ball and washer The washer The select return spring The select return spring bolt Tighten Tighten the select return spring bolt to 35 N.m (25 ft lbs).
61. Apply Loctite® 599 RTV silicone sealer or equivalent to the following surfaces: The rear case The gearshift lever case mating surfaces
62. Install the gearshift lever case to the rear case. Secure the gearshift lever case with 5 bolts. Tighten Tighten the gearshift lever case bolts to 16 N.m (12 ft lbs).
63. Apply J 36850 to the speedometer driven gear case O-ring.
64. Install the speedometer driven gear case. Secure the speedometer driven gear case with 1 bolt. Tighten Tighten the speedometer driven gear case retaining bolt to 10 N.m (89 in lbs).
65. Inspect the four-wheel drive switch O-ring for cuts or damage. Replace as necessary.
66. Apply J 36850 to the four-wheel drive switch O-ring.
67. Install the following components into the rear case: The steel ball (2) The four-wheel drive switch (1) Tighten Tighten the four-wheel drive switch to 19 N.m (14 ft lbs). (Scheme 75): Installing Steel Ball & Four-Wheel Drive Switch Into Rear Case
68. Inspect the four-wheel drive low switch O-ring for cuts or damage. Replace as necessary.
69. Apply J 36850 to the four-wheel drive low switch O-ring.
70. Install the steel ball and the four-wheel drive low switch into the rear case. Tighten Tighten the four-wheel drive low switch to 19 N.m (14 ft lbs).

Identifying Special Tools (1 Of 4). Scheme 76

Identifying Special Tools (2 Of 4). Scheme 77

Identifying Special Tools (3 Of 4). Scheme 78

Identifying Special Tools (4 Of 4). Scheme 79