Transfer Case - Bw 4484: Removal & Installation Hummer H2 I

Removal Procedure

1. Remove the knee bolster. Refer to «Trim Panel Replacement - Knee Bolster»(ref-187217-S19396169522005083100000) in Instrument Panel, Gauges, and Console.
2. Disconnect the shift control module electrical connectors.
3. Reposition the harness.
4. Remove the module from the vehicle.

Installation Procedure

1. Install the shift control module to the vehicle.
2. Connect the shift control module electrical connectors.
3. Install the knee bolster. Refer to «Trim Panel Replacement - Knee Bolster»(ref-187217-S19396169522005083100000) in Instrument Panel, Gauges, and Console.
4. Start the engine and test the automatic transfer case system for proper shift operation.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the transfer case shield mounting bolts from the cross member.
3. Remove the transfer case shield from cross member.

1. Install the transfer case shield to the cross member.
2. Install the transfer case shield mounting bolts the cross member. Tighten: Tighten the mounting bolts to 30 N.m (23 lb ft).
3. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the fill plug from the transfer case.
3. Remove the drain plug from the transfer case.

1. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug.
2. Install the drain plug in the transfer case. Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
3. Fill the transfer case to the bottom of the fill hole with the proper fluid.
4. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug.
5. Install the fill plug. Tighten: Tighten the fill plug to 25 N.m (18 lb ft).
6. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

1. Remove the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-187236-S34971654712005083100000) .
2. Disconnect the encoder motor electrical connector.
3. Remove the encoder motor bolts.
4. Remove the encoder motor.
5. Remove the actuator insulator.

1. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the sealing surface of the encoder motor.
2. Rotate to align the shift detent lever with the encoder motor assembly and install the encoder motor.
3. Loosely install the encoder motor mounting bolts.
4. Loosely install the encoder motor bracket bolt. Tighten: Tighten the Encoder motor mounting bolts and the bracket bolt to 10 N.m (89 lb in).
5. Connect the encoder motor electrical connector.
6. Install the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-187236-S34971654712005083100000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the electrical connector from the speed sensor.
3. Remove the speed sensor and the O-ring from the transfer case.

1. Install the new rear speed sensor into the transfer case with a new O-ring seal. Tighten: Tighten the speed sensor to 17 N.m (13 lb ft).
2. Install the electrical connector to the speed sensor.
3. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

Transfer Case Output Shaft Seal Replacement - Front

Tools Required

1. J 8092 Universal Handle
2. J 43484 Front Output Shaft Seal Installer. See «Special Tools and Equipment»(ref-187236-S16618157412005083100000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the front propeller shaft from the vehicle. Refer to «Propeller Shaft Replacement - Front»(ref-187279-S29249493512005083100000) in Propeller Shaft.
3. Insert a flat-tipped screw driver in the inner race.
4. Pry the inner race forward.
5. Insert a small pry bar in the inner race.
6. Pry the inner part of the seal from the outer seal body.
7. Remove the inner part of the seal.
8. Insert a flat-tipped screw driver or small pry bar in the space between the outer race of the seal and the transfer case.
9. Pry the outer race out of the transfer case.
10. Remove the outer part of the seal.

1. Using the J 43484 (2) and the J 8092 (1), install the transfer case output seal. See «Special Tools and Equipment»(ref-187236-S16618157412005083100000) .
2. Install the front propeller shaft. Refer to «Propeller Shaft Replacement - Front»(ref-187279-S29249493512005083100000) in Propeller Shaft.
3. Check the transfer case fluid level. Refer to «Transfer Case Fluid Replacement»(ref-187236-S10137636132005083100000) .
4. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement - Rear»(ref-187279-S17531687712005083100000) in Propeller Shaft.
3. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver.

1. Using J 45756 , install a NEW front output shaft seal. See «Special Tools and Equipment»(ref-187236-S16618157412005083100000) .
2. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement - Rear»(ref-187279-S17531687712005083100000) in Propeller Shaft.
3. Check the fluid level. Add fluid, if necessary.
4. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Drain the transfer case. Refer to «Transfer Case Fluid Replacement»(ref-187236-S10137636132005083100000) .
3. Drain the transmission fluid. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) in Automatic Transmission - 4L60-E/4L65-E.
4. Remove the transmission support member. Refer to «Transmission Support Replacement»(ref-187245-S27632739092005083100000) .
5. Remove the rear propeller shaft from the transfer case. Refer to «Propeller Shaft Replacement - Rear»(ref-187279-S17531687712005083100000) in Propeller Shaft.
6. Remove the front propeller shaft from the transfer case. Refer to «Propeller Shaft Replacement - Front»(ref-187279-S29249493512005083100000) in Propeller Shaft.
7. Remove the vent hoses from the transfer case and transmission.
8. Disconnect the electrical connector from the speed sensor.
9. Disconnect the encoder motor from the electrical connector.
10. Remove the fuel lines from the retainer at the top of the transfer case.
11. Install a suitable transmission jack to the transfer case.
12. Remove the bolts from the transfer case to the adapter.
13. Remove the transfer case from the transfer case adapter.
14. Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
15. Lower the transfer case.
16. Remove the gasket from the transfer case.
17. Remove the transfer case from the transmission jack.

1. Install the transfer case on a suitable transmission jack.
2. Install a new transfer case gasket.
3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
4. Raise the transfer case into position.
5. Rotate the transfer case so that the transfer case is aligned with the adapter.
6. Install the transfer case on the adapter.
7. Install the mounting nuts for the transfer case. Tighten: Tighten the mounting nuts to 50 N.m (37 lb ft).
8. Connect the vent hoses to the transfer case and transmission.
9. Connect the vehicle speed sensor and encoder motor electrical connectors.
10. Install the fuel lines into the retainer at the top of the transfer case.
11. Install the transmission support member. Refer to «Transmission Support Replacement»(ref-187245-S27632739092005083100000) .
12. Remove the transmission jack.
13. Install the front propeller shaft. Refer to «Propeller Shaft Replacement - Front»(ref-187279-S29249493512005083100000) in Propeller Shaft.
14. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement - Rear»(ref-187279-S17531687712005083100000) in Propeller Shaft.
15. Fill the transfer case with the proper transfer case fluid. Refer to «Transfer Case Fluid Replacement»(ref-187236-S10137636132005083100000) .
16. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
17. Fill the transmission fluid with the proper fluid. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) in Automatic Transmission - 4L60-E/4L65-E.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Remove the transfer case from the adapter. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) .
3. Using the J 36825 remove the input shaft seal from the transfer case by threading the self tapping screw (2) into the seal. See «Special Tools and Equipment»(ref-187236-S16618157412005083100000) .

1. Position the seal on the input shaft.
2. Using the J 42738 , install the input shaft seal in the transfer case. See «Special Tools and Equipment»(ref-187236-S16618157412005083100000) .
3. Install the transfer case to the adapter. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) .
4. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
2. Support the transmission with a suitable jack stand.
3. Remove the rear crossmember from the frame.
4. Remove the transfer case from the vehicle. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) .
5. Remove the mounting bolts from the adapter to the transmission.
6. Remove the adapter from the transmission (automatic shown).
7. Remove the seal between the transfer case and the adapter.
8. Remove the gasket from the adapter.

1. Install the new seal onto the transfer case.
2. Install the adapter to the transmission.
3. Install the adapter mounting bolts to the transmission. Tighten: Tighten the mounting bolts to 50 N.m (36 lb ft).
4. Install the new gasket to the adapter.
5. Install the transfer case to the adapter. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) .
6. Install the crossmember in the vehicle. Tighten: Tighten the mounting bolts to 95 N.m (70 lb ft).
7. Remove the transmission jack from the transmission.
8. Check the fluid level of the transfer case. Refer to «Transfer Case Fluid Replacement»(ref-187236-S10137636132005083100000) .
9. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.

1. Remove the instrument panel (I/P) cluster bezel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-187217-S32969193842005083100000) in Instrument Panel, Gauges, and Console.
2. Using a flat-tipped screwdriver, gently pry the retaining clips open on the housing.
3. Slide out the selector switch until the electrical connectors are accessible.
4. Disconnect the selector switch electrical connectors.
5. Remove the selector switch from the housing.

1. Position the selector switch close to the housing so the electrical connectors can be connected.
2. Connect the selector switch electrical connectors.
3. Slide the selector switch into the housing until the switch snaps into place. IMPORTANT: Make sure that the selector switch is seated properly in the housing before installing the I/P cluster bezel.
4. Install the I/P cluster bezel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-187217-S32969193842005083100000) in Instrument Panel, Gauges, and Console.