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Transfer Case - Getrag 760: Removal & Installation GMC Terrain I

Transfer Case 22 illustrations ~2431 words

Removal Procedure

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Remove the drain plug (2).
  3. Remove the fill plug (1).

Installation Procedure

  1. Clean and inspect the drain plug and case sealing surfaces.
  2. Install the drain plug (2) and tighten to 39 (29 lb ft).
  3. Fill the transfer case with gear lubricant to the bottom of the fill plug, or 0.80 L (0.85 qt). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491200-S33833622172012073000000) .
  4. Install the fill plug (1) and tighten to 39 (29 lb ft).
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Remove the drain plug (2).
  3. Remove the fill plug (1).
  1. Clean and inspect the drain plug and case sealing surfaces.
  2. Install the drain plug (2) and tighten to 39 (29 lb ft).
  3. Fill the transfer case with gear lubricant to the bottom of the fill plug, or 0.80 L (0.85 qt). Refer to «Adhesives, Fluids, Lubricants, and Sealers»(ref-491200-S33833622172012073000000) .
  4. Install the fill plug (1) and tighten to 39 (29 lb ft).
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Remove the fill plug (1).
  1. Clean the fill plug and apply adhesive GM P/N 12345493 (Canadian P/N 10953488) to the threads.
  2. Install the fill plug (1) and tighten to 39 N.m (29 lb ft).
  3. Lower the vehicle.

Scheme 1

Scheme 1: Transfer Case Brace Replacement (LFW Engine)
Scheme 1: Transfer Case Brace Replacement (LFW Engine)
CalloutComponent Name
Preliminary Procedures Raise the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
1Transfer Case Brace Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . TIP: Tighten the fasteners in the specified sequential order. Tighten 50 N.m (37 lb ft)
2Transfer Case Brace Bolt TIP: Tighten the fasteners in the specified sequential order. Tighten 50 N.m (37 lb ft)
3Transfer Case Brace Bolt (Qty: 3) TIP: Tighten the fasteners in the specified sequential order. Tighten 23 N.m (17 lb ft)
4Transfer Case Brace
CAUTION
Refer to Fastener Caution .

Transfer Case Brace Replacement (LFW Engine)

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  5. Remove the transfer case rear output shaft flange. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  4. Remove the intermediate shaft bearing seal, snap ring and intermediate drive shaft assembly from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  2. Install the intermediate shaft assembly and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the intermediate drive shaft bearing shield.
  4. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  5. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  6. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  4. Remove the intermediate shaft bearing seal, snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  5. Remove the half shaft retainer, O-ring seal, intermediate shaft bearing retainers and bearing from the intermediate drive shaft. Refer to Intermediate Drive Shaft Disassembly in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  1. Install the intermediate shaft bearing, retainers, O-ring seal and half shaft retainer to the intermediate drive shaft. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the intermediate drive shaft bearing shield.
  4. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  5. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  6. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  4. Remove the intermediate shaft bearing seal, snap ring and intermediate drive shaft from the transfer case. Refer to Intermediate Drive Shaft Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  2. Install the intermediate shaft and snap ring into the transfer case. Refer to Intermediate Drive Shaft Assembly in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the intermediate drive shaft bearing shield.
  4. Install the transfer case assembly (2). Refer to «Transfer Case Assembly Replacement»(ref-491200-S35994025932012073000000) .
  5. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  6. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Remove the right front wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  3. Remove the intermediate drive shaft bearing shield.
  1. Install the intermediate drive shaft bearing shield.
  2. Install the right front wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  3. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Remove the rear output shaft housing. Refer to Rear Output Shaft Housing Removal in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  5. Remove the transfer case rear output shaft flange and seal. Refer to Rear Output Shaft Housing Disassembly in «Transfer Case Disassemble»(ref-491200-S17373471612012073000000) .
  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-491200-S35164689532012073000000) .
  2. Install the rear output shaft housing. Refer to Rear Output Shaft Housing Installation in «Transfer Case Assemble»(ref-491200-S35164689532012073000000) .
  3. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Drain the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(ref-491164-S06618089182012073000000) , for the 6T30/6T40/6T45 or «Transmission Fluid Drain and Fill»(ref-491165-S29354967312012073000000) for the 6T70/6T75.
  4. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  5. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  6. Remove the catalytic converter. For the LFW engine, refer to «Catalytic Converter Replacement - Right Side (LFW)»(ref-491179-S03656845662012073000000) , and for the LAF engine refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
  7. Remove the transfer case brace (3). Refer to «Transfer Case Brace Replacement (LFW Engine)»(ref-491200-S18835683582012073000000) .
  8. Remove the transfer case mounting bracket (3).
  9. Support the transaxle with a jackstand.
  10. Remove the rear transmission mount and bracket. Refer to «Transmission Rear Mount Bracket Replacement (AWD)»(ref-491164-S20397636822012073000000) , «Transmission Rear Mount Bracket Replacement (FWD)»(ref-491164-S17779236392012073000000) .
  11. Remove the bolts (1) securing the transfer case to the transaxle.
  12. Remove the transfer case (2) from the transaxle.
  13. Remove the transfer case to transmission O-ring for (LFW) engine or the gasket for (LAF) engine.
  1. Install a NEW the transfer case to transmission O-ring for LFW engine or NEW gasket for LAF engine. Lube the O-ring with light coating of automatic transmission fluid.
  2. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
  3. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  4. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
  5. 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.
  6. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
  7. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.
  8. Install the transfer case (2) to the transaxle.
  9. Remove the guide pins.
  10. Install the bolts (1) securing the transfer case to the transaxle and tighten the bolts to 50 (37 lb ft).
  11. Install the rear transmission mount and bracket. Refer to «Transmission Rear Mount Bracket Replacement (AWD)»(ref-491164-S20397636822012073000000) , «Transmission Rear Mount Bracket Replacement (FWD)»(ref-491164-S17779236392012073000000) .
  12. Remove the jackstand supporting the transaxle.
  13. Install the transfer case brace (3). Refer to «Transfer Case Brace Replacement (LFW Engine)»(ref-491200-S18835683582012073000000) .
  14. Install the catalytic converter. For the LFW engine, refer to «Catalytic Converter Replacement - Right Side (LFW)»(ref-491179-S03656845662012073000000) , and for the LAF engine refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
  15. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  16. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  17. Fill the transmission fluid. Refer to «Transmission Fluid Drain and Fill»(ref-491164-S06618089182012073000000) , for the 6T30/6T40/6T45 or «Transmission Fluid Drain and Fill»(ref-491165-S29354967312012073000000) for the 6T70/6T75.
  18. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  19. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Drain the transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  3. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  4. Remove the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  5. Remove the catalytic converter. For the LFW engine, refer to «Catalytic Converter Replacement - Right Side (LFW)»(ref-491179-S03656845662012073000000) , and for the LAF engine refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
  6. Remove the transfer case brace (3). Refer to «Transfer Case Brace Replacement (LFW Engine)»(ref-491200-S18835683582012073000000) .
  7. Remove the transfer case mounting bracket (3).
  8. Support the transaxle with a jackstand.
  9. Remove the rear transmission mount and bracket. Refer to «Transmission Rear Mount Bracket Replacement (AWD)»(ref-491164-S20397636822012073000000) , «Transmission Rear Mount Bracket Replacement (FWD)»(ref-491164-S17779236392012073000000) .
  10. Remove the bolts (1) securing the transfer case to the transaxle.
  11. Remove the transfer case (2) from the transaxle.
  12. Remove the transfer case to transmission O-ring for (LFW) engine or the gasket for (LAF) engine.
  1. Install a NEW the transfer case to transmission O-ring for LFW engine or NEW gasket for LAF engine. Lube the O-ring with light coating of automatic transmission fluid.
  2. Install the transfer case (2) to the transaxle.
  3. Install the bolts (1) securing the transfer case to the transaxle and tighten the bolts to 50 (37 lb ft).
  4. Install the rear transmission mount and bracket. Refer to «Transmission Rear Mount Bracket Replacement (AWD)»(ref-491164-S20397636822012073000000) , «Transmission Rear Mount Bracket Replacement (FWD)»(ref-491164-S17779236392012073000000) .
  5. Remove the jackstand supporting the transaxle.
  6. Install the transfer case brace (3). Refer to «Transfer Case Brace Replacement (LFW Engine)»(ref-491200-S18835683582012073000000) .
  7. Install the catalytic converter. For the LFW engine, refer to «Catalytic Converter Replacement - Right Side (LFW)»(ref-491179-S03656845662012073000000) , and for the LAF engine refer to «Catalytic Converter Replacement (LEA-FWD)»(ref-491179-S29424249042012073000000) , «Catalytic Converter Replacement (LEA-AWD)»(ref-491179-S07030702382012073000000) .
  8. Install the right wheel drive shaft. Refer to «Front Wheel Drive Shaft Replacement»(ref-491185-S02622697212012073000000) .
  9. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  10. Fill the transfer case with fluid. Refer to «Transfer Case Fluid Replacement»(ref-491200-S11189150812012073000000) .
  11. Lower the vehicle.

Scheme 2

Scheme 2: Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Scheme 2: Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
CalloutComponent Name
1Transfer Case Input Shaft Face Seal - RPO MHC Only
2Transfer Case O-ring Seal - RPO MH4 Only
3Transfer Case Vent Assembly TIP: Remove the vent only if damaged or blocked.
4Transfer Case Bracket-to-Transfer Case Bolts (Qty: 2)
5Transfer Case Bracket
6Transfer Case Heat Shield Bolts (Qty: 3) - Model Dependent
7Transfer Case Heat Shield - Model Dependent
8Transfer Case Drain Plug
9Transfer Case Fill Plug

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

Scheme 3

Scheme 3: Intermediate Drive Shaft Removal
Scheme 3: Intermediate Drive Shaft Removal
CalloutComponent Name
1Front Wheel Drive Retainer
2Front Wheel Drive Intermediate Shaft

Intermediate Drive Shaft Removal

Scheme 4

Scheme 4: Rear Output Shaft Housing Removal
Scheme 4: Rear Output Shaft Housing Removal
CalloutComponent Name
1Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2Transfer Case Rear Output Shaft Housing TIP: 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 TIP: Discard the O-ring after removal.

Rear Output Shaft Housing Removal

Scheme 5

Scheme 5: Right Transfer Case, Input and Output Drive Shaft Removal
Scheme 5: Right Transfer Case, Input and Output Drive Shaft Removal
CalloutComponent Name
1Transfer Case Half Bolts (Qty: 12)
2Transfer Case - Right
3Transfer Case Seal-to-Transfer Case - Right
4Transfer Case Input Shaft
5Transfer Case Rear Output Drive Shaft
6Transfer Case Half Locating Pins (Qty: 2) Remove the pins only if damaged. Inspect the case for similar damage. Refer to Transfer Case Cleaning and Inspection .

Right Transfer Case, Input and Output Drive Shaft Removal

Scheme 6

Scheme 6: Rear Output Shaft Housing Disassembly
Scheme 6: Rear Output Shaft Housing Disassembly
CalloutComponent Name
1Transfer Case Rear Output Drive Gear Nut TIP: Use a 30 mm socket. Special Tools DT-08614-A Pinion Flange Holder and Remover For equivalent regional tools, refer to Special Tools
2Transfer Case Rear Output Shaft Flange Special Tools DT-48146 Press Support For equivalent regional tools, refer to Special Tools
3Transfer Case Rear Output Shaft Bearing Assembly TIP: 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 TIP: Remove the slinger only if damaged. Refer to Rear Output Drive Housing Cleaning and Inspection .
7Transfer Case Rear Output Shaft Seal TIP: Discard the seal after removal.

Rear Output Shaft Housing Disassembly

Scheme 7

Scheme 7: Intermediate Drive Shaft Disassembly
Scheme 7: Intermediate Drive Shaft Disassembly
CalloutComponent Name
1Half Shaft Retainer
2O-Ring
3Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)
4Front Wheel Drive Intermediate Shaft Bearing Assembly TIP: Use a press, with the Rear Pinion and Axle Bearing Remover flat side up, in order to remove the bearing assembly. Special Tools J-22912-BJ 22912-B Rear Pinion and Axle Bearing Remover For equivalent regional tools, refer to Special Tools .

Intermediate Drive Shaft Disassembly

Scheme 8

Scheme 8: Transfer Case Cleaning and Inspection
Scheme 8: Transfer Case Cleaning and Inspection
CalloutComponent Name
CAUTION: Refer to Machined Surface Damage Caution . Preliminary Procedure Clean the left and right transfer case housings in cleaning solvent and air dry. The transfer case internal components are not to be serviced. If the internal components are damaged, the transfer case must be replaced.
1Transfer Case- Left and Right TIP: 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 TIP: Repair small scratches or nicks with light sanding.
3Case Sealing Surface TIP: Repair small scratches or nicks with a soft stone.
4Transfer Case Bearing Races TIP: Replace the transfer case assembly if a bearing has spun or if cracks are detected.
5Transfer Case Thread Bolt Holes TIP: Repair any damaged threads.
6Transfer Case Half Locating Pin Holes
CAUTION
Refer to Machined Surface Damage Caution .

Transfer Case Cleaning and Inspection

Scheme 9

Scheme 9: Rear Output Drive Housing Cleaning and Inspection
Scheme 9: 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 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 TIP: Replace the slinger if damaged, cracked, loose, or distorted.
3Transfer Case Rear Output Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.
4Transfer Case Rear Output Shaft Housing 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 TIP: Inspect for damage and press fit to flange.
6Transfer Case Rear Output Shaft TIP: Inspect for pitting, excessive wear, or damage.

Rear Output Drive Housing Cleaning and Inspection

Scheme 10

Scheme 10: Input Shaft Seal Replacement - Right
Scheme 10: 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 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 the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface.

Input Shaft Seal Replacement - Right

Scheme 11

Scheme 11: Input Shaft Seal Replacement - Left (RPO MH4)
Scheme 11: Input Shaft Seal Replacement - Left (RPO MH4)
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 (A) should be 17.6 +/- 0.5 mm (0.693 +/- 0.02 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 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.

Input Shaft Seal Replacement - Left (RPO MH4)

Scheme 12

Scheme 12: Input Shaft Seal Replacement - Left (RPO MHC)
Scheme 12: Input Shaft Seal Replacement - Left (RPO MHC)
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 (A) should be 80.0 +/- 0.5 mm (3.15 +/- 0.02 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 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.

Input Shaft Seal Replacement - Left (RPO MHC)

Scheme 13

Scheme 13: Front Drive Axle Inner Shaft Seal Replacement
Scheme 13: Front Drive Axle Inner Shaft Seal Replacement
CalloutComponent Name
1Front Drive Axle Intermediate Shaft Seal Assembly TIP: Inner Drive Shaft Seal Installer seats the seal to a specific depth. Other installation methods may set the seal to a non-functional depth. Special Tools DT 48078DT-48078 Inner Drive Shaft Seal Installer J 8092 Driver Handle For equivalent regional tools, refer to Special Tools .

Front Drive Axle Inner Shaft Seal Replacement

Scheme 14

Scheme 14: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
Scheme 14: 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 TIP: Inspect for pitting, excessive wear, or damage.
2Transfer Case Rear Output Drive Shaft Gear TIP: Inspect for pitting, excessive wear, or damage.
3Transfer Case Input Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.
4Transfer Case Rear Output Drive Shaft Bearing Assembly TIP: Inspect bearings for roughness, spalling, or pitting.

Input Shaft and Rear Output Drive Shaft Cleaning and Inspection

Scheme 15

Scheme 15: Intermediate Drive Shaft Assembly
Scheme 15: Intermediate Drive Shaft Assembly
CalloutComponent Name
1Transfer Case Intermediate Drive Shaft
2Transfer Case Intermediate Drive Shaft Bearing Retainers (Qty: 2)
3Transfer Case Intermediate Drive Shaft Bearing Assembly TIP: 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 16

Scheme 16: Rear Output Shaft Housing Assembly
Scheme 16: 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 TIP: 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 TIP: 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 17

Scheme 17: Output Flange Installation
Scheme 17: Output Flange Installation
CalloutComponent Name
1Transfer Case Rear Output Shaft Oil Slinger TIP: 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 TIP: 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 . The rear output shaft nut is supplied with a dry retaining compound patch. If reusing the nut, apply retaining compound to the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers . Use a 30 mm socket or the J-29873 Injector Nozzle Socket 30 mm and the DT-08614-A Pinion Flange Holder and Remover. Tighten 235 N.m (173 lb ft) Special Tools DT-08614-A Pinion Flange Holder and Remover For equivalent regional tools, refer to Special Tools
CAUTION
Refer to Fastener Caution .

Output Flange Installation

Scheme 18

Scheme 18: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
Scheme 18: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
CalloutComponent Name
1Transfer Case Half Locating Pins
2Transfer Case Input Shaft TIP: 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 Bolts (Qty: 12) 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 19

Scheme 19: Rear Output Shaft Housing Installation
Scheme 19: 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. Use of a heat gun allows easy alignment of the bolt holes to the housing during assembly. Install the rear output shaft housing with the flat area aligned to the tab on the main housing. Rotate the pinion gear during assembly to engage the gear teeth. Special Tools EL-25070 Heat Gun - 500-750F For equivalent regional tools, refer to Special Tools
4Transfer Case Rear Output Shaft Housing Bolts (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 20

Scheme 20: Intermediate Drive Shaft Installation
Scheme 20: 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 Installation Guide Shaft 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

Scheme 21

Scheme 21: Housing O-ring, Vent Assembly, Drain and Fill Plug Installation
Scheme 21: Housing O-ring, Vent Assembly, Drain and Fill Plug Installation
CalloutComponent Name
1Transfer Case Input Shaft Face Seal - RPO MHC Only
2Transfer Case O-ring Seal - RPO MH4 Only
3Transfer Case Vent Assembly TIP: Replace the vent if damaged or blocked.
4Drain Plug CAUTION: Refer to Component Fastener Tightening Caution . Tighten 39 N.m (29 lb ft)
5Fill Plug Tighten 39 N.m (29 lb ft)
6Transfer Case Heat Shield - Model Dependent
7Transfer Case Heat Shield Bolts (Qty: 3) - Model Dependent CAUTION: Refer to Fastener Caution . Tighten 11 N.m (97 lb in)
8Transfer Case Bracket
9Transfer Case Bracket Bolts (Qty: 2) TIP: Tighten the bracket bolts to light assembly torque. Tighten to specification after the transfer case is mounted in the vehicle. Refer to Fastener Tightening Specifications .
CAUTION
Refer to Component Fastener Tightening Caution .
CAUTION
Refer to Fastener Caution .

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

Scheme 22

Scheme 22: Transfer Case Description and Operation
Scheme 22: Transfer Case Description and Operation

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