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Transfer Case - Getrag 790: Removal & Installation GMC Acadia I рестайлинг

Transfer Case 26 illustrations ~2423 words

Installation Procedure

  1. Clean the drain plug.
  2. Install the drain plug and tighten to 39 (29 lb ft). CAUTION: Refer to «Component Fastener Tightening Caution»(ref-610030-S39845292282014042100000) .
  3. 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-610118-S30229669762014042100000) for lubricant recommendation.
  4. Clean the fill plug.
  5. Install the fill plug and tighten to 39 (29 lb ft).
  6. Lower the vehicle.

Removal Procedure

  1. Remove the fill plug.
  1. Install the fill plug and tighten to 39 (29 lb ft). CAUTION: Refer to «Component Fastener Tightening Caution»(ref-610030-S39845292282014042100000) .

Scheme 3

Scheme 3: Transfer Case Vent Hose Replacement
Scheme 3: Transfer Case Vent Hose Replacement
CalloutComponent Name
1Transfer Case Vent Hose
2Transfer Case Vent Nipple
3Hose Clamp
4Engine Assembly Procedure Disconnect electrical connectors as necessary. Transfer components as necessary.

Transfer Case Vent Hose Replacement

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the transfer case rear output shaft flange and seal. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  1. Install the transfer case rear output shaft seal. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  1. Install the transfer case rear output shaft flange and slinger. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  6. Remove the transfer case rear output shaft oil slinger from the transfer case rear output shaft flange.
  1. Install the transfer case rear output shaft flange and slinger. Refer to Rear Output Shaft Housing Assembly and Output Flange Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.

Scheme 4

Scheme 4: Removal Procedure
Scheme 4: Removal Procedure
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the O-ring, half shaft retainer, intermediate shaft bearing retainer and bearing from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  1. Install the O-ring, half shaft retainer, intermediate shaft bearing retainer and bearing to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) . NOTE: Special tool DT-48094 must be used to install the intermediate shaft.
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the intermediate shaft bearing retainers and bearing from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  1. Install the intermediate shaft bearing and retainers to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) . NOTE: Special tool DT-48094 must be used to install the intermediate shaft.
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Remove the intermediate shaft snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the half shaft retainer and O-ring seal from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  1. Install the O-ring seal and half shaft retainer to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) . NOTE: Special tool DT-48094 must be used to install the intermediate shaft.
  3. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-610118-S24014298532014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-610118-S14795865122014042100000) .
  5. Remove the transfer case rear output shaft housing seal O-ring.
  1. Install the transfer case rear output shaft housing seal O-ring.
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-610118-S41965411522014042100000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Drain the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(ref-610059-S29192582162014042100000) .
  4. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  5. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-610098-S20248897622014042100000) .
  6. Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-610075-S30854594592014042100000) .
  7. Support the transaxle with a jackstand.
  8. Remove the engine rear mount bracket. Refer to «Engine Rear Mount Bracket Replacement (Front Wheel Drive)»(ref-610074-S20752197502014042100000) and «Engine Rear Mount Bracket Replacement (All Wheel Drive)»(ref-610074-S16267444212014042100000) .
  9. Remove the transfer case bolts (1).
  10. Remove the transfer case (2).

Scheme 5

Scheme 5: Installation Procedure
Scheme 5: Installation Procedure

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Lubricate the O-rings (2, 3) with automatic transmission fluid.
  2. Install the NEW transfer case O-ring seal (3).
  3. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission. NOTE: Oxidation must be removed from the transmission torque converter housing bore before installation of the transfer case. A clean bore will prevent oxidation build up from scuffing or cutting the O-ring seal upon transfer case installation, resulting in a leak.
  4. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  5. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
  6. 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. NOTE: Use guide pins to aid in alignment and installation of the transfer case to the transmission. Failure to use guide pins may result in cutting the transfer case O-ring seal during installation of the transfer case causing a fluid leak.
  7. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
  8. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case. NOTE: Transmission fluid may creep from the transmission bore during installation.
  9. Install the transfer case (1) to the transmission.
  10. Remove the guide pins (2).
  11. Install the transfer case to transmission bolts (1) and tighten to 50 N.m (37 lb ft). CAUTION: Refer to «Fastener Caution»(ref-610030-S34989781762014042100000) .
  12. Install the engine rear mount bracket. Refer to «Engine Rear Mount Bracket Replacement (Front Wheel Drive)»(ref-610074-S20752197502014042100000) , «Engine Rear Mount Bracket Replacement (All Wheel Drive)»(ref-610074-S16267444212014042100000) .
  13. Remove the jackstand from under the transaxle.
  14. Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-610075-S30854594592014042100000) .
  15. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-610098-S20248897622014042100000) .
  16. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  17. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  18. Fill the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(ref-610059-S29192582162014042100000) .
  19. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-610031-S32962375812014042100000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  3. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  4. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-610098-S20248897622014042100000) .
  5. Remove the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-610075-S30854594592014042100000) .
  6. Support the transaxle with a jackstand.
  7. Remove the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(ref-610074-S26686706632014042100000) .
  8. Remove the transfer case bolts (1).
  9. Remove the transfer case (2).
  1. Lubricate the O-rings (2, 3) with automatic transmission fluid.
  2. Install the NEW transfer case O-ring seal (3).
  3. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission. NOTE: Oxidation must be removed from the transmission torque converter housing bore before installation of the transfer case. A clean bore will prevent oxidation build up from scuffing or cutting the O-ring seal upon transfer case installation, resulting in a leak.
  4. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  5. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
  6. 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. NOTE: Use guide pins to aid in alignment and installation of the transfer case to the transmission. Failure to use guide pins may result in cutting the transfer case O-ring seal during installation of the transfer case causing a fluid leak.
  7. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
  8. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case. NOTE: Transmission fluid may creep from the transmission bore during installation.
  9. Install the transfer case (1) to the transmission.
  10. Remove the guide pins (2).
  11. Install the transfer case to transmission bolts (1) and tighten to 50 N.m (37 lb ft). CAUTION: Refer to «Fastener Caution»(ref-610030-S34989781762014042100000) .
  12. Install the engine rear mount bracket. Refer to «Engine Rear Mount Replacement»(ref-610074-S26686706632014042100000) .
  13. Remove the jackstand from under the transaxle.
  14. Install the exhaust flexible pipe. Refer to «Exhaust Flexible Pipe Replacement»(ref-610075-S30854594592014042100000) .
  15. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-610098-S20248897622014042100000) .
  16. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-610076-S04226847072014042100000) .
  17. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-610118-S03749771642014042100000) .
  18. Lower the vehicle.

Scheme 10

Scheme 10: Housing O-ring, Vent Assembly, Drain and Fill Plug Removal
Scheme 10: Housing O-ring, Vent Assembly, Drain and Fill Plug Removal
CalloutComponent Name
1Transfer Case O-ring Seal
2Transfer Case Vent Assembly NOTE: Remove the vent only if damaged or blocked.
3Transfer Case Drain Plug
4Transfer Case Fill Plug
NOTE
Remove the vent only if damaged or blocked.

Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal

Scheme 11

Scheme 11: Intermediate Drive Shaft Removal
Scheme 11: Intermediate Drive Shaft Removal
CalloutComponent Name
1Front Wheel Drive Retainer
2Front Wheel Drive Intermediate Shaft

Intermediate Drive Shaft Removal

Scheme 12

Scheme 12: Rear Output Shaft Housing Removal
Scheme 12: Rear Output Shaft Housing Removal
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2Transfer Case Rear Output Shaft Housing NOTE: Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal.
3Transfer Case Rear Output Shim
4Transfer Case Rear Output Shaft Housing Seal O-ring NOTE: Discard the O-ring after removal.
NOTE
Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal.
NOTE
Discard the O-ring after removal.

Rear Output Shaft Housing Removal

Scheme 13

Scheme 13: Right Transfer Case, Input and Output Drive Shaft Removal
Scheme 13: Right Transfer Case, Input and Output Drive Shaft Removal
CalloutComponent Name
1Transfer Case Half Bolt (Qty: 11)
2Transfer Case - Right
3Transfer Case Seal from the Transfer Case - Right
4Transfer Case Input Shaft
5Transfer Case Rear Output Drive Shaft
6Transfer Case Half Locating Pin (Qty: 2) NOTE: Remove the pins only if damaged. Inspect the case for similar damage. Refer to Transfer Case Cleaning and Inspection .
NOTE
Remove the pins only if damaged. Inspect the case for similar damage.

Right Transfer Case, Input and Output Drive Shaft Removal

Scheme 14

Scheme 14: Rear Output Shaft Housing Disassembly
Scheme 14: Rear Output Shaft Housing Disassembly
CalloutComponent Name
1Transfer Case Rear Output Shaft Gear Nut Procedure Use a 30 mm socket or J-29873 Nozzle Socket 30 mm. Special Tools J-08614-A Pinion Flange Holder and Remover J 29873 Nozzle Socket 30 mm For equivalent regional tools, refer to Special Tools .
2Transfer Case Rear Output Shaft Flange Special Tools DT-48145 Press Support For equivalent regional tools, refer to Special Tools .
3Transfer Case Rear Output Shaft Bearing Assembly NOTE: Use a press to remove the output shaft from the housing.
4Transfer Case Rear Output Shaft Bearing Spacer
5Transfer Case Rear Output Shaft
6Transfer Case Rear Output Shaft Oil Slinger NOTE: Remove the slinger only if damaged. Refer to Rear Output Drive Housing Cleaning and Inspection .
7Transfer Case Rear Output Shaft Seal NOTE: Discard the seal after removal.
NOTE
Use a press to remove the output shaft from the housing.
NOTE
Remove the slinger only if damaged.
NOTE
Discard the seal after removal.

Rear Output Shaft Housing Disassembly

Scheme 15

Scheme 15: Intermediate Drive Shaft Disassembly
Scheme 15: Intermediate Drive Shaft Disassembly
CalloutComponent Name
1Half Shaft Retainer
2O-ring
3Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
4Front Wheel Drive Intermediate Shaft Bearing Assembly Procedure Use a press, with the J 22912-B Rear Pinion and Axle Bearing Remover flat side up, in order to remove the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools .

Intermediate Drive Shaft Disassembly

Scheme 16

Scheme 16: Transfer Case Cleaning and Inspection
Scheme 16: Transfer Case Cleaning and Inspection
CalloutComponent 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.
1Transfer Case - Left and Right NOTE: Inspect for cracks, broken areas or other damage. The transfer case assembly must be replaced if damage is found.
2Transfer Case Rear Output Drive Housing Bore NOTE: Repair small scratches or nicks with light sanding.
3Case Sealing Surface NOTE: Repair small scratches or nicks with a soft stone.
4Transfer Case Bearing Races NOTE: Replace the transfer case assembly if a bearing has spun or if cracks are detected.
5Transfer Case Thread Bolt Holes NOTE: Repair any damaged threads.
6Transfer Case Half Locating Pin Holes
CAUTION
Refer to Machined Surface Damage Caution .
NOTE
Inspect for cracks, broken areas or other damage. The transfer case assembly must be replaced if damage is found.
NOTE
Repair small scratches or nicks with light sanding.
NOTE
Repair small scratches or nicks with a soft stone.
NOTE
Replace the transfer case assembly if a bearing has spun or if cracks are detected.
NOTE
Repair any damaged threads.

Transfer Case Cleaning and Inspection

Scheme 17

Scheme 17: Rear Output Drive Housing Cleaning and Inspection
Scheme 17: Rear Output Drive Housing Cleaning and Inspection
CalloutComponent Name
Preliminary Procedures Clean all components in cleaning solvent and air dry. The transfer case internal components are not to be serviced. If internal components other than seals are damaged, the transfer case must be replaced.
1Transfer Case Rear Output Shaft Flange NOTE: Replace if flange, threaded holes or splines are damaged. Inspect sealing surface for corrosion, excessive wear or damage.
2Transfer Case Rear Output Shaft Oil Slinger NOTE: Replace the slinger if damaged, cracked, loose or distorted.
3Transfer Case Rear Output Shaft Bearing Assembly NOTE: Inspect bearings for roughness, spalling or pitting.
4Transfer Case Rear Output Shaft Housing NOTE: 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.
5Transfer Case Rear Output Shaft Splines NOTE: Inspect for damage and press fit to flange.
6Transfer Case Rear Output Shaft NOTE: Inspect for pitting, excessive wear or damage.
NOTE
Replace if flange, threaded holes or splines are damaged. Inspect sealing surface for corrosion, excessive wear or damage.
NOTE
Replace the slinger if damaged, cracked, loose or distorted.
NOTE
Inspect bearings for roughness, spalling or pitting.
NOTE
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.
NOTE
Inspect for damage and press fit to flange.
NOTE
Inspect for pitting, excessive wear or damage.

Rear Output Drive Housing Cleaning and Inspection

Scheme 18

Scheme 18: Input Shaft Seal Replacement - Right
Scheme 18: Input Shaft Seal Replacement - Right
CalloutComponent Name
1Transfer 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 J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in 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.

Input Shaft Seal Replacement - Right

Scheme 19

Scheme 19: Input Shaft Seal Replacement - Left
Scheme 19: Input Shaft Seal Replacement - Left
CalloutComponent Name
1Transfer 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 Lightly lubricate the outer diameter (OD) of the seal with clean gear lube prior to installation. 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. NOTE: 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 J-8092 Driver Handle DT-26941/KM-J-26941 Bushing and Bearing Remover - 3-4 in DT-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.
NOTE
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.

Input Shaft Seal Replacement - Left

Scheme 20

Scheme 20: Front Drive Axle Inner Shaft Seal Replacement
Scheme 20: Front Drive Axle Inner Shaft Seal Replacement
CalloutComponent Name
1Front Drive Axle Intermediate Shaft Seal Assembly NOTE: 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 .
NOTE
DT-48078 seal installer seats the seal to a specific depth. Other installation methods may set the seal to a non-functional depth.

Front Drive Axle Inner Shaft Seal Replacement

Scheme 21

Scheme 21: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
Scheme 21: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
CalloutComponent Name
Preliminary Procedures Clean all components in cleaning solvent and air dry. The transfer case internal components are not to be serviced. If internal components other than seals are damaged, the transfer case must be replaced.
1Transfer Case Input Shaft Gear NOTE: Inspect for pitting, excessive wear or damage.
2Transfer Case Rear Output Drive Shaft Gear NOTE: Inspect for pitting, excessive wear or damage.
3Transfer Case Input Shaft Bearing Assembly NOTE: Inspect bearings for roughness, spalling or pitting.
4Transfer Case Rear Output Drive Shaft Bearing Assembly NOTE: Inspect bearings for roughness, spalling or pitting.
NOTE
Inspect for pitting, excessive wear or damage.
NOTE
Inspect for pitting, excessive wear or damage.
NOTE
Inspect bearings for roughness, spalling or pitting.
NOTE
Inspect bearings for roughness, spalling or pitting.

Input Shaft and Rear Output Drive Shaft Cleaning and Inspection

Scheme 22

Scheme 22: Intermediate Drive Shaft Assembly
Scheme 22: Intermediate Drive Shaft Assembly
CalloutComponent Name
1Front Wheel Drive Intermediate Shaft
2Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
3Front Wheel Drive Intermediate Shaft Bearing Assembly Procedure Use a press, with the DT-22912-B/KM-307-B Rear Pinion and Axle Bearing Remover flat side up, in order to install the bearing assembly. Special Tools DT-22912-B/KM-307-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools .
4O-ring
5Half Shaft Retainer

Intermediate Drive Shaft Assembly

Scheme 23

Scheme 23: Rear Output Shaft Housing Assembly
Scheme 23: Rear Output Shaft Housing Assembly
CalloutComponent Name
1Transfer Case Rear Output Shaft
2Transfer Case Rear Output Shaft Bearing Spacer
3Transfer Case Rear Output Shaft Housing
4Transfer Case Rear Output Shaft Bearing Assembly Procedure Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the housing and bearings to the output shaft. Special Tools J-5590 Pinion Bearing Race Installer - Rear For equivalent regional tools, refer to Special Tools .
5Transfer Case Rear Output Shaft Seal Procedure Use a press with the DT-48075 Output Shaft Seal Installer to install the seal. Special Tools DT-48075 Output Shaft Seal Installer For equivalent regional tools, refer to Special Tools .

Rear Output Shaft Housing Assembly

Scheme 24

Scheme 24: Output Flange Installation
Scheme 24: Output Flange Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Oil Slinger Procedure Use a press with the DT-48077 Output Shaft Slinger Installer in order to install the slinger. Special Tools DT-48077 Output Shaft Slinger Installer For equivalent regional tools, refer to Special Tools .
2Transfer Case Rear Output Shaft Flange Procedure Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the flange. Special Tools J-5590 Pinion Bearing Race Installer - Rear For equivalent regional tools, refer to Special Tools .
3Transfer Case Rear Output Shaft Nut CAUTION: Refer to Fastener Caution . Procedure 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 Pinion Flange Holder and Remover and a 30 mm socket or the EN-29873 Injector Nozzle Socket 30 mm. Tighten 235 (173 lb ft) Special Tools J-08614-A Pinion Flange Holder and Remover EN-29873 Injector Nozzle Socket 30 mm For equivalent regional tools, refer to Special Tools .
CAUTION
Refer to Fastener Caution .

Output Flange Installation

Scheme 25

Scheme 25: Right Transfer Case, Input Shaft and Output Drive Shaft Installation
Scheme 25: Right Transfer Case, Input Shaft and Output Drive Shaft Installation
CalloutComponent Name
1Transfer Case Half Locating Pin (Qty: 2)
2Transfer Case Input Shaft NOTE: Install the input and output shafts as a set with the splines engaged.
3Transfer Case Rear Output Drive Shaft
4Transfer Case Seal to the Transfer Case - Right
5Transfer Case - Right
6Transfer Case Half Bolt (Qty: 11) CAUTION: Refer to Fastener Caution Tighten 29 (21 lb ft)
NOTE
Install the input and output shafts as a set with the splines engaged.
CAUTION
Refer to Fastener Caution

Right Transfer Case, Input Shaft and Output Drive Shaft Installation

Scheme 26

Scheme 26: Rear Output Shaft Housing Installation
Scheme 26: Rear Output Shaft Housing Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Seal O-ring
2Transfer Case Rear Output Shim
3Transfer 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. NOTE: 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 EL-25070 Heat Gun - 500-750°F For equivalent regional tools, refer to Special Tools .
4Transfer Case Rear Output Shaft Housing Bolt (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten 29 (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.
NOTE
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.
CAUTION
Refer to Fastener Caution .

Rear Output Shaft Housing Installation

Scheme 27

Scheme 27: Intermediate Drive Shaft Installation
Scheme 27: Intermediate Drive Shaft Installation
CalloutComponent Name
1Front 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 For equivalent regional tools, refer to Special Tools .
2Front 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

CalloutComponent Name
1Transfer Case O-ring Seal
2Transfer Case Vent Assembly NOTE: Replace the vent if damaged or blocked.
3Drain Plug CAUTION: Refer to Fastener Caution . Tighten 39 (29 lb ft)
4Fill Plug Tighten 39 (29 lb ft)
NOTE
Replace the vent if damaged or blocked.
CAUTION
Refer to Fastener Caution .

Housing O-ring, Vent Assembly, Drain and Fill Plug Installation

Scheme 28

Scheme 28: Transfer Case Description and Operation
Scheme 28: Transfer Case Description and Operation

The transfer case in this vehicle consists of an aluminum housing with input helical gear, output driven helical gear, ring and pinion hypoid gear set and an intermediate drive shaft.

The transfer case transfers torque/power to the on-demand rear differential through a prop shaft assembly.

The on-demand rear differential distributes variable torque/power to the rear wheels through individual axle shafts.

Within the rear differential assembly is an active on-demand coupling system.

The on-demand system rear differential control module monitors wheel speed, vehicle speed, wheel slippage and other variables. The module directs the rear differential to distribute torque to the rear wheels as required.

Typical conditions when torque is applied are during vehicle launches, even without wheel slip and when there is front wheel slippage relative to the rear wheels. The amount of torque depends on the vehicle speed and the amount of wheel slippage.

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