GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 3289-20 Holding Fixture
    • J 22912-B Split Plate Bearing Puller
    • J 23907 Slide Hammer with Bearing Adapter
    • J 26941 Bushing and Bearing Remover - 3-4 inch
    • J 36825 Output Shaft Oil Seal Remover - 4WD Models Only
    • J 45358 Case Spreader
    • J 45759 Assembly Fixture
    • J 45849 Bearing Remover

    Object Number: 824077  Size: SH
  1. Mount the J 3289-20 to a sturdy workbench.
  2. Attach the J 45759 on the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 .

  3. Object Number: 823195  Size: SH
  4. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.

  5. Object Number: 823193  Size: SH
  6. Remove the drain plug. Ensure all of the transfer case fluid is drained out of the transfer case.
  7. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 819585  Size: SH

    Important: The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.

  8. Remove the front input shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
  9. Pry the inner seal race forward.

  10. Object Number: 819650  Size: SH
  11. Using a small pry bar, move the inner seal race forward on the front input shaft.
  12. Remove the inner seal race from the front input shaft.

  13. Object Number: 819658  Size: SH
  14. Insert a flat-tipped screwdriver or a small pry bar between the lip of the outer lip of the front output shaft seal and the transfer case.
  15. Remove the remaining part of the front output shaft seal from the transfer case.

  16. Object Number: 823198  Size: SH
  17. Remove the vehicle speed sensor (VSS) with O-ring seal.
  18. Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.


    Object Number: 823202  Size: SH
  19. Remove the rear output shaft seal by prying out with a flat-blade screwdriver.

  20. Object Number: 823204  Size: SH
  21. Remove the transfer case retaining bolts and the washers.
  22. Mark the location of the brackets.
  23. Notice: Refer to Machined Surface Damage Notice in the Preface section.


    Object Number: 819584  Size: SH
  24. Using the J 45358 between the tabs on the case halves, shear the sealer holding the case halves together.
  25. Using pry bars at each side of the case, remove the case from the locating pins.

  26. Object Number: 823209  Size: SH
  27. Remove the rear case half from the front case half. The rear output shaft will come out with the rear case half.

  28. Object Number: 823196  Size: SH
  29. Remove the planetary carrier assembly thrust washer.

  30. Object Number: 823206  Size: SH
  31. Remove the planetary carrier assembly.

  32. Object Number: 823207  Size: SH
  33. Remove the sun gear thrust washer.

  34. Object Number: 823211  Size: SH
  35. Remove the front input shaft.

  36. Object Number: 819620  Size: SH
  37. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.

  38. Object Number: 823213  Size: SH

    Important: If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.

  39. Remove the chain with the driven sprocket.

  40. Object Number: 823216  Size: SH
  41. Remove the sun gear with the drive gear and viscous coupling. Lift up on the sun gear assembly while tapping down on the input shaft with a soft-face hammer.

  42. Object Number: 823218  Size: SH
  43. Using a hydraulic press and J 22912-B , remove the bearing from the sun gear.

  44. Object Number: 823220  Size: SH
  45. Remove the drive gear from the sun gear.

  46. Object Number: 823221  Size: SH
  47. Remove the viscous coupling from the sun gear.

  48. Object Number: 823222  Size: SH
  49. Remove the input shaft from the front case.

  50. Object Number: 819621  Size: SH
  51. Using the J 23907  (1) and the J 36825  (2), remove the input seal.
  52. 29.1. Poke a hole in the seal using a very sharp punch.
    29.2. Thread the J 36825  (2) into the hole.

    Object Number: 823226  Size: SH
  53. Remove the input shaft bushing from the front case using a hammer and brass drift.

  54. Object Number: 819623  Size: SH
  55. Using a brass drift, remove the front output shaft bearing from the front case half.

  56. Object Number: 823229  Size: SH
  57. If necessary, remove the vent from the front case half.

  58. Object Number: 823230  Size: MH

    Important: Depending on the build date of the transfer case, it may have a rear output shaft bearing with or without a retaining ring groove. In early build transfer cases, the retaining ring (1) for the rear output shaft bearing was in front of the bearing (2). In later build transfer cases, the retaining ring (3) was moved rearward 5 mm (0.197 in) in the case. The bearings (4) have a groove and the retaining ring is installed in the groove.

  59. Remove the rear output shaft from the rear case half.
  60. 33.1. Spread the rear output shaft rear bearing outer retaining ring.
    33.2. Using a soft-face hammer, tap on the end of the rear output shaft.

    Object Number: 823231  Size: SH
  61. Remove the annulus gear retaining ring.

  62. Object Number: 823232  Size: SH
  63. Remove the rear output shaft from the annulus gear.

  64. Object Number: 823235  Size: SH
  65. Inspect the bearing in the rear output shaft. Refer to Transfer Case Cleaning and Inspection .
  66. If the bearing is faulty, remove the bearing using the J 45849 .
  67. • Install the finger part of the J 45849 in the bearing.
    • Thread the driver part into the fingers.
    • Remove the bearing from the fingers by squeezing the fingers together.

    Object Number: 823236  Size: SH
  68. Remove the retaining ring for the rear output shaft bearing and the speed reluctor wheel.

  69. Object Number: 823237  Size: SH
  70. Using a hydraulic press and the J 22912-B , remove the speed reluctor wheel and the rear output shaft bearing
  71. Do not use the speed reluctor wheel again.


    Object Number: 819636  Size: SH
  72. Remove the rear bearing for the front output shaft from the rear case, using the J 26941  (1) and the J 23907  (2).