Removal Procedure
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-365243-S07204316382010070600000) .
- Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-365262-S25119686372010070600000) .
- Remove the drain plug.
- Remove the fill plug.
Installation Procedure
- Clean the drain plug.
- Install the drain plug. Tighten: Tighten the drain plug to 39 N.m (29 lb ft).
- Fill the transfer case with lubricant to the bottom of the fill plug, or 1 Liter (34 oz.). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-365299-S03534973092010070600000) for lubricant recommendation.
- Clean the fill plug.
- Install the fill plug. Tighten: Tighten the fill plug to 39 N.m (29 lb ft).
- Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-365262-S25119686372010070600000) .
- Lower the vehicle.
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-365243-S07204316382010070600000) .
- Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-365299-S25602427222010070600000) .
- Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-365267-S32728570342010070600000) .
- Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-365290-S28433612192010070600000) .
- Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-365262-S25119686372010070600000) .
- Support the transaxle with a jackstand.
- Remove the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(ref-365266-S23415975522010070600000) .
- Remove the transfer case bolts (1).
- Remove the transfer case (2).
- Remove the half shaft retainer (1).
- Remove the shaft O-ring seal (2).
- Remove the transfer case O-ring seal (3), then discard the O-ring.
- Lubricate the O-rings (2, 3) with petroleum jelly.
- Install the shaft O-ring seal (2).
- Install the half shaft retainer (1).
- Install the NEW transfer case O-ring seal (3).
- Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
- Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
- Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
- Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
- Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
- Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.
- Install the transfer case (1) to the transmission.
- Remove the guide pins (2).
- Install the transfer case to transmission bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
- Install the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(ref-365266-S23415975522010070600000) .
- Remove the jackstand from under the transaxle.
- Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-365262-S25119686372010070600000) .
- Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-365290-S28433612192010070600000) .
- Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-365267-S32728570342010070600000) .
- Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-365299-S25602427222010070600000) .
- Lower the vehicle.
Scheme 1
Scheme 1: Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case O-Ring Seal |
| 2 | Transfer Case Vent Assembly Tip: Remove the vent only if damaged or blocked. |
| 3 | Transfer Case Drain Plug |
| 4 | Transfer Case Fill Plug |
Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Scheme 2
Scheme 2: Intermediate Drive Shaft Removal
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Retainer |
| 2 | Front Wheel Drive Intermediate Shaft Special Tools: J 25070 Heat Gun - 500-750F For equivalent regional tools, refer to Special Tools . |
Intermediate Drive Shaft Removal
Scheme 3
Scheme 3: Rear Output Shaft Housing Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft Housing Bolt (Qty: 6) |
| 2 | Transfer Case Rear Output Shaft Housing Tip: Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal. Special Tools: J 25070 Heat Gun - 500-750F |
| 3 | Transfer Case Rear Output Shim |
| 4 | Transfer Case Rear Output Shaft Housing Seal O-Ring Tip: Discard the O-ring after removal. |
Rear Output Shaft Housing Removal
Scheme 4
Scheme 4: Right Transfer Case, Input and Output Drive Shaft Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case Half Bolt (Qty: 11) |
| 2 | Transfer Case - Right |
| 3 | Transfer Case Seal |
| 4 | Transfer Case Input Shaft |
| 5 | Transfer Case Rear Output Drive Shaft |
| 6 | Transfer Case Half Locating Pin (Qty: 2) Refer to Transfer Case Cleaning and Inspection . Tip: Remove the pins only if damaged. Inspect the case for similar damage. |
Right Transfer Case, Input and Output Drive Shaft Removal
Scheme 5
Scheme 5: Rear Output Shaft Housing Disassembly
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft Gear Nut Tip: Use a 30 mm socket or J 29873 . See Special Tools . Special Tools: J-08614-A Pinion Flange Holder and Remover. See Special Tools . |
| 2 | Transfer Case Rear Output Shaft Flange Special Tools: DT-48145 Press Support. See Special Tools . |
| 3 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Use a press to remove the output shaft from the housing. |
| 4 | Transfer Case Rear Output Shaft Bearing Spacer |
| 5 | Transfer Case Rear Output Shaft |
| 6 | Transfer Case Rear Output Shaft Oil Slinger Refer to Rear Output Drive Housing Cleaning and Inspection . Tip: Remove the slinger only if damaged. |
| 7 | Transfer Case Rear Output Shaft Seal Tip: Discard the seal after removal. |
Rear Output Shaft Housing Disassembly
Scheme 6
Scheme 6: Intermediate Drive Shaft Disassembly
| Callout | Component Name |
|---|
| 1 | Half Shaft Retainer |
| 2 | O-Ring |
| 3 | Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2) |
| 4 | Front Wheel Drive Intermediate Shaft Bearing Assembly Tip: Use a press, with the J 22912-B flat side up, in order to remove the bearing assembly. Special Tools: J 22912-B Rear Pinion and Axle Bearing Remover |
Intermediate Drive Shaft Disassembly
Scheme 7
Scheme 7: Transfer Case Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: Refer to Machined Surface Damage Caution . Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean the left and right transfer case in cleaning solvent and air dry. |
| 1 | Transfer Case - Left and Right Tip: Inspect for cracks, broken areas, or other damage. The transfer case assembly must be replaced if damage is found. |
| 2 | Transfer Case Rear Output Drive Housing Bore Tip: Repair small scratches or nicks with light sanding. |
| 3 | Case Sealing Surface Tip: Repair small scratches or nicks with a soft stone. |
| 4 | Transfer Case Bearing Races Tip: Replace the transfer case assembly if a bearing has spun or if cracks are detected. |
| 5 | Transfer Case Thread Bolt Holes Tip: Repair any damaged threads. |
| 6 | Transfer Case Half Locating Pin Holes |
| CAUTION |
|---|
| Refer to Machined Surface Damage Caution . |
Scheme 8
Scheme 8: Rear Output Drive Housing Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry. The transfer case rear output drive housing is not serviced. If damage cannot be repaired, the transfer case must be replaced. |
| 1 | Transfer Case Rear Output Shaft Flange Tip: Replace if flange, threaded holes, or splines are damaged. Inspect sealing surface for corrosion, excessive wear, or damage. |
| 2 | Transfer Case Rear Output Shaft Oil Slinger Tip: Replace the slinger if damaged, cracked, loose, or distorted. |
| 3 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
| 4 | Transfer Case Rear Output Shaft Housing Tip: Inspect for cracks, broken areas, or other damage. Inspect bearing races for roughness, brinelling, or pitting. Inspect the O-ring channel for porosity or damage. Scratches or nicks in other areas may be repaired with light sanding. |
| 5 | Transfer Case Rear Output Shaft Splines Tip: Inspect for damage and press fit to flange. |
| 6 | Transfer Case Rear Output Shaft Tip: Inspect for pitting, excessive wear, or damage. |
Scheme 9
Scheme 9: Input Shaft Seal Replacement - Right
| Callout | Component Name |
|---|
| 1 | Transfer Case Input Shaft Seal - Right CAUTION: Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. Special Tools DT-48074 Input and Output Shaft Seal Installer. See Special Tools . J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in. See Special Tools . J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. |
Scheme 10
Scheme 10: Input Shaft Seal Replacement - Left
| Callout | Component Name |
|---|
| 1 | Transfer Case Input Shaft Seal - Left CAUTION: Do not use a screwdriver or punch to remove or install the seal. Using a screwdriver or punch to remove or install the seal may damage the aluminum housing sealing surface. Procedure: To ensure proper alignment and depth of the seal, take four measurements every 90 degrees around the seal circumference, verifying uniform depth. The distance from the top face of the machined surface of the bore to the metal flange of the seal should be 24.3 +/- 0.1 mm (0.957 +/- 0.004 in). Failure to follow these instructions will result in replacement seal failure. Tip: Alignment of seal is critical and use of correct tool is necessary. The machined surface of the bore must be clean and free from scratches or nicks. Special Tools DT-48074 Input and Output Shaft Seal Installer. See Special Tools . J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in. See Special Tools . J 45124 Removal Bridge For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Do not use a screwdriver or punch to remove or install the seal. Using a screwdriver or punch to remove or install the seal may damage the aluminum housing sealing surface. |
Scheme 11
Scheme 11: Front Drive Axle Inner Shaft Seal Replacement
| Callout | Component Name |
|---|
| 1 | Front Drive Axle Intermediate Shaft Seal Assembly Tip: DT-48078: seal installer seats the seal to a specific depth. Other installation methods may set the seal to a non-functional depth. Special Tools DT-48078: Inner Drive Shaft Seal Installer J 8092: Universal Driver For equivalent regional tools, refer to Special Tools . |
Scheme 12
Scheme 12: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry. The transfer case input shaft and transfer case rear output drive shaft is not serviced. If damage cannot be repaired, the transfer case must be replaced. |
| 1 | Transfer Case Input Shaft Gear Tip: Inspect for pitting, excessive wear, or damage. |
| 2 | Transfer Case Rear Output Drive Shaft Gear Tip: Inspect for pitting, excessive wear, or damage. |
| 3 | Transfer Case Input Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
| 4 | Transfer Case Rear Output Drive Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
Scheme 13
Scheme 13: Intermediate Drive Shaft Assembly
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Intermediate Shaft |
| 2 | Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2) |
| 3 | Front Wheel Drive Intermediate Shaft Bearing Assembly Tip: Use a press, with the J 22912-B flat side up, in order to install the bearing assembly. Special Tools: J 22912-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools . |
| 4 | O-Ring |
| 5 | Half Shaft Retainer |
Intermediate Drive Shaft Assembly
Scheme 14
Scheme 14: Rear Output Shaft Housing Assembly
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft |
| 2 | Transfer Case Rear Output Shaft Bearing Spacer |
| 3 | Transfer Case Rear Output Shaft Housing |
| 4 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Use a press with the J 5590 to install the housing and bearings to the output shaft. Special Tools: J 5590 Pinion Bearing Race Installer - Rear |
| 5 | Transfer Case Rear Output Shaft Seal Tip: Use a press with the DT-48075 to install the seal. See Special Tools . Special Tools: DT-48075 Output Shaft Seal Installer. See Special Tools . |
Rear Output Shaft Housing Assembly
Scheme 15
Scheme 15: Output Flange Installation
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft Oil Slinger Tip: Use a press with the DT-48077 in order to install the slinger. See Special Tools . Special Tools: DT-48077 Output Shaft Slinger Installer. See Special Tools . |
| 2 | Transfer Case Rear Output Shaft Flange Tip: Use a press with the J 5590 to install the flange. Special Tools: J 5590 Pinion Bearing Race Installer - Rear |
| 3 | Transfer Case Rear Output Shaft Nut CAUTION: Refer to Fastener Caution Tip: The rear output shaft nut is supplied with a dry retaining compound patch. If reusing the nut, apply GM P/N 12345382 (Canadian P/N 10953489) to the threads. Use the J-08614-A and a 30 mm socket or the J 29873 . See Special Tools . Tighten: 235 N.m (173 lb ft) Special Tools J-08614-A Pinion Flange Holder and Remover. See Special Tools . J 29873 Injector Nozzle Socket 30 mm. See Special Tools . |
| CAUTION |
|---|
| Refer to Fastener Caution |
Output Flange Installation
Scheme 16
Scheme 16: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
| Callout | Component Name |
|---|
| 1 | Transfer Case Half Locating Pin (Qty: 2) |
| 2 | Transfer Case Rear Output Drive Shaft |
| 3 | Transfer Case Input Shaft Tip: Install the input and output shafts as a set with the splines engaged. |
| 4 | Transfer Case Seal |
| 5 | Transfer Case - Right |
| 6 | Transfer Case Half Bolt (Qty: 11) CAUTION: Refer to Fastener Caution Tighten: 29 N.m (21 lb ft) |
| CAUTION |
|---|
| Refer to Fastener Caution |
Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
Scheme 17
Scheme 17: Rear Output Shaft Housing Installation
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft Housing Seal O-Ring |
| 2 | Transfer Case Rear Output Shim |
| 3 | Transfer Case Rear Output Shaft Housing CAUTION: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth. Tip: Use of a heat gun allows easy alignment of the bolt holes to the housing during assembly. Rotate the pinion gear during assembly to engage the gear teeth. Special Tools: J 25070 Heat Gun - 500-750F |
| 4 | Transfer Case Rear Output Shaft Housing Bolt (Qty: 6) CAUTION: Refer to Fastener Caution Tighten: 29 N.m (21 lb ft) |
| CAUTION |
|---|
| Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth. |
| CAUTION |
|---|
| Refer to Fastener Caution |
Rear Output Shaft Housing Installation
Scheme 18
Scheme 18: Intermediate Drive Shaft Installation
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Intermediate Shaft CAUTION: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage. Special Tools DT-48094 Inner Drive Shaft Seal Protector. See Special Tools . J 25070 Heat Gun - 500-750F |
| 2 | Front Wheel Drive Retainer |
| CAUTION |
|---|
| DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage. |
Intermediate Drive Shaft Installation
Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation
| Callout | Component Name |
|---|
| 1 | Transfer Case O-Ring Seal |
| 2 | Transfer Case Vent Assembly Tip: Replace the vent if damaged or blocked. |
| 3 | Drain Plug CAUTION: Refer to Fastener Caution Tighten: 39 N.m (29 lb ft) |
| 4 | Fill Plug Tighten: 39 N.m (29 lb ft) |
| CAUTION |
|---|
| Refer to Fastener Caution |
Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation
All-Wheel Drive Description and Operation
This vehicle is equipped with the Rear Differential Clutch Control Module for AWD Vehicles.
The vehicle is equipped with the following system and operation
- System distributes torque evenly between the 2 rear wheels.
- The system distributes torque to the rear wheels to enhance traction and improve vehicle handling performance.
- The rear differential clutch control assembly contains a main clutch, pilot clutch, electromagnetic coil, rear wheel shaft, main cam, pilot cam.
- The clutch control module operates by utilizing a clutch pack for transferring torque. The engagement mechanism consists of an electromagnetic coil and armature which modulates torque through a pilot clutch and thrust amplification device.
- The rear differential has a micro computer which receives information from the clutch control module (CCM).
- The CCM has an internal temperature sensor, which will maintain consistent and continuous temperature compensation for torque transfer from -40°C to +120°C. When the temperature of the module is determined to be beyond its limits, the CCM will temporarily disable the rear drive system and turn on the AWD Disabled message. When the temperature of the module is back within the limits, the CCM will enable the rear drive system. The temperature sensor and coil are internal to the rear differential, and is replace as an assembly.
- If the vehicle is being driven very aggressively, and or an unexpected tire size has been used, the AWD disabled message will be turned on. This should not result in the replacement of CCM module.
- The AWD disable message will be turned on if the mini-spare tire or a very small sized tire has been installed. This should not result in the replacement of CCM module.
- The clutch coil receives current from the CCM which is used to modulate torque through the use of the engagement mechanism. The greater the current the greater the torque. The safe current range is between 0.1-3.0-amps. If the current range is not within those values we have DTCs that set and the Service AWD message will appear. The temperature sensor and coil are internal to the differential, and is replace as an assembly.
- The module uses vehicle speed, steering angle, wheel slip, thermal compensation, and chassis control intervention to determine current. These are messages on GMLAN from other modules.
- Replace the CCM, the CCM needs to be configured for the clutch control calibrations. The connector on the clutch (that plugs into the CCM) will have a 2 digit value. Use that 2 digit value to program the CCM using the Tech 2.
- Voltage for our module is between 5-24 volts. We set a low voltage code but not a high voltage code as we can withstand a voltage up to 24 volts.
- Displays 2 messages in DIC or IP. Amber AWD Disabled (All Wheel Drive Off) - DIC Service All Wheel Drive.
Scheme 19
Scheme 19: Transfer Case Description and Operation
The Getrag 790 transfer case consists of an aluminum housing, input shaft and gear, and a ring and pinion power transfer system.
The Getrag 790 transfer case transfers torque/power from the input shaft through the ring and pinion assembly to the rear differential via a 1-piece propeller shaft assembly.
The on-demand rear differential and torque tube assembly distributes variable torque/power to the rear wheels via individual axle shafts.
The Getrag 790 transfer case is a single speed unit. Torque transfer is electronically controlled, dependent on the demand of the rear differential.
The power take-off unit (PTU) uses synthetic hypoid gear lubricant, which is intended for lifetime service. Full fluid level is at the bottom of the fill plug hole when the vehicle is on a level surface.
