1

Transfer Case Input Shaft Bearing Assembly

2

Transfer Case Input Shaft Inner Retaining Ring

3

Transfer Case High/Low Planetary Carrier Assembly

4

Transfer Case Planetary Carrier Sun Gear Thrust Washer

5

Transfer Case Input Shaft

6

Transfer Case Planetary Carrier Sun Gear Thrust Washer

7

Transfer Case High/Low Locking Plate

8

Transfer Case High/Low Planetary Carrier Retaining Ring

9

Transfer Case Input Shaft/Planetary Assembly

10

Transfer Case Input Shaft Bearing Outer Retaining Ring

1

Transfer Case Rear Output Shaft

2

Transfer Case Two/Four Wheel Drive Synchronizer Hub

3

Transfer Case Two/Four Wheel Drive Synchronizer Insert (Qty: 3)

Tip
Ensure that the inserts are installed in the correct orientation in the synchronizer hub. The inserts should be able to move when correctly installed.

4

Transfer Case Two/Four Wheel Drive Synchronizer Sleeve

5

Transfer Case Two/Four Wheel Drive Synchronizer Assembly

6

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring

7

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring

8

Transfer Case Front Output Shaft Drive Sprocket

9

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

10

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

11

Transfer Case Oil Pump Assembly

12

Transfer Case Rear Output Shaft Speed Reluctor Wheel

13

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

14

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip

15

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

Preliminary Procedure

1

Transfer Case High/Low Clutch

2

Transfer Case Two/Four Wheel Drive Shift Fork Assembly

3

Transfer Case High/Low Shift Fork Assembly

4

Transfer Case Rear Output Shaft Assembly

1

Transfer Case Front Output Shaft Assembly, Transfer Case Front Output Shaft Drive Chain Assembly

Tip

2

Transfer Case Shift Fork Spring

3

Transfer Case Oil Pump Suction Pipe Seal

Tip

4

Transfer Case Oil Pump Suction Pipe

1

Transfer Case Two/Four Wheel Drive Actuator Seal

2

Sealer GM P/N 12345739 (Canadian P/N 10953541) or Equivalent

Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

Tip

3

Transfer Case Rear Case Half

Tip

4

Transfer Case Bracket

5

Transfer Case Bolts (Qty: 17)

Notice: Refer to Fastener Notice in the Preface section.

Tip
Tighten the bolts by hand. Do not use an air gun.

Tighten
25 N·m (18 lb ft)

1

Transfer Case Rear Output Shaft Seal (Heavy Duty and Super Heavy Duty)

Tip
Align the notch on the seal between the rear output bearing retaining ring access holes. This will position the weep hole down.

Special Tools

2

Transfer Case Shift Detent Plunger

3

Transfer Case Shift Detent Spring

4

Transfer Case Shift Detent Plunger Plug Seal

Tip
Lightly lubricate the O-ring with clean DEXRON®VI.

5

Transfer Case Shift Detent Plunger Plug

Notice: Refer to Component Fastener Tightening Notice in the Preface section.

Tighten
20 N·m (15 lb ft)

1

Transfer Case Two/Four Wheel Drive Actuator Assembly

2

Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw

Notice: Refer to Fastener Notice in the Preface section.

Tighten
18 N·m (13 lb ft)

3

Transfer Case Oil Fill Plug

Tip
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil fill plug before installation.

Tighten
18 N·m (13 lb ft)

4

Transfer Case Oil Drain Plug

Tip
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil drain plug before installation.

Tighten
18 N·m (13 lb ft)

5

Transfer Case Vent

Tip
Apply retaining compound GM P/N 12377901 (Canadian P/N 10953504) to the vent pipe before installation, if removed during disassembly.

6

Vehicle Speed Sensor O-Ring Seal

Tip
Lightly lubricate the O-ring with clean DEXRON®VI.

7

Vehicle Speed Sensor Assembly

Tighten
17 N·m (13 lb ft)

8

Transfer Case Access Hole Plugs (Qty: 2)

1

Transfer Case Input Shaft Seal

Tip
Ensure the bore of the front case half is free of dirt, oil, and cleaning solvent.

Special Tools

J 42738 Seal Installer

2

Transfer Case Front Output Shaft Seal

Special Tools

3

Transfer Case Assembly

Tip
Remove from the J 3289-20 and remove the J 45759 from the transfer case.