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

Preliminary Procedure

1

Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plates (Qty: 8)

Tip
Install the friction and steel clutch plates into the DT-48213 gage , alternating until 8 friction plates and 7 steel plates are installed.

Special Tools

DT-48213 Clutch Pack Height Gage

For equivalent regional tools, refer to Special Tools.

2

Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plates (Qty: 7)

Procedure 1 - Outside Measurement:

1. Tighten the DT-48213 gage until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
2. Using an outside caliper, measure the total combined height of the clutch pack and the DT-48213 gage , dimension a. Subtract the thickness of both the upper and lower portion of the DT-48213 gage , 14 mm (0.551 in), and record the results.
3. Repeat the process in 2 additional locations, 120 degrees from each other.
4. The average of the 3 measurements is the clutch pack height.

Procedure 2 - Inside Measurement:

1. Tighten the DT-48213 gage until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates.
2. Using an inside caliper, measure the height of the clutch pack, dimension b, and record the results.
3. Repeat the process in 2 additional locations, 120 degrees from each other.
4. The average of the 3 measurements is the clutch pack height.

Tip
Install the friction and steel clutch plates into the DT-48213 gage , alternating until 8 friction plates and 7 steel plates are installed.

Special Tools

DT-48213 Clutch Pack Height Gage

1

Transfer Case Rear Output Shaft

2

Transfer Case Control Actuator Lever Thrust Bearing Assembly

3

Transfer Case Control Lever

4

Transfer Case Control Actuator Lever Bearing Assembly

5

Transfer Case Control Actuator Lever Ball (Qty: 3)

6

Transfer Case Control Actuator Lever Assembly

7

Transfer Case Control Actuator Lever Thrust Bearing Assembly

8

Transfer Case Control Actuator Lever Washer

9

Transfer Case Four Wheel Drive Clutch Pressure - Apply - Plate

Tip
Ensure the control actuator lever washer is seated into the apply plate groove.

10

Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4)

11

Transfer Case Four Wheel Drive Clutch Hub

12

Transfer Case Four Wheel Drive Clutch Shim

Tip

13

Transfer Case Two/Four Wheel Drive Clutch Retaining Ring

Tip
If the clutch shim is not seated against the retaining ring, replace the clutch pressure plate springs.

1

Clutch Assembly

Procedure:

1. Using an inside caliper, measure the height of the clutch assembly in the location shown and record the results.
2. Repeat the process in 2 additional locations, 120 degrees from each other.
3. The average of the 3 measurements is the clutch assembly height.
4. A 3.1 mm (0.122 in) clearance +/- 0.1 mm (0.004 in) is necessary between the clutch pack height and the assembly height. It may be necessary to replace the clutch shim with a thicker shim or a thinner shim, to achieve the proper clearance in the clutch.
5. Subtract the clutch pack height from the clutch assembly height. The difference should be between 3.0 mm (0.118 in) and 3.2 mm (0.126 in) clearance.

Tip

•	A variety of shims are available to properly adjust the clearance height of the clutch assembly.

•	An inside micrometer may also be used to measure the clutch assembly height.

1

Transfer Case Control Actuator Lever Washer

2

Transfer Case Four Wheel Drive Clutch Pressure - Apply - Plate

3

Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4)

4

Transfer Case Four Wheel Drive Clutch Pressure Plates

5

Transfer Case Four Wheel Drive Clutch Hub

6

Transfer Case Four Wheel Drive Clutch Shim

7

Transfer Case Two/Four Wheel Drive Clutch Retaining Ring

Tip
The Transfer Case High/Low Clutch Reset must be performed after the transfer case is installed in the vehicle.

1

Transfer Case Front Output Shaft Drive Sprocket Spacer - Front

2

Transfer Case Four Wheel Drive Clutch Housing

3

Transfer Case Front Output Shaft Drive Sprocket

4

Transfer Case Four Wheel Drive Clutch Housing Retaining Ring

5

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

6

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

7

Transfer Case Oil Pump Assembly

8

Transfer Case Rear Output Shaft Speed Reluctor Wheel

9

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

10

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip

11

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

Preliminary Procedure

Load all 3 components simultaneously.

1

Transfer Case High/Low Shift Fork Assembly

2

Transfer Case High/Low Clutch

3

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 Actuator Shaft Gear

3

Transfer Case Oil Pump Suction Pipe Seal

Tip

4

Transfer Case Oil Pump Suction Pipe

1

Sealer GM P/N 12345739 (Canadian P/N 10953541), or equivalent

Caution: 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

2

Transfer Case Rear Case Half

Tip

3

Transfer Case Bracket

4

Transfer Case Bolts (Qty: 17)

Caution: Refer to Fastener Caution in the Preface section.

Tip
Tighten bolts by hand, do not use an air gun.

Tighten
25 N·m (18 lb ft)

Preliminary Procedures

The following procedure is for the light duty application, for the heavy duty and super heavy duty applications. Refer to Rear Output Shaft Bushing Replacement.

1

Transfer Case Rear Output Shaft Bushing (Light Duty)

Tip

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

2

Transfer Case Rear Output Shaft Seal (Light 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

3

Transfer Case Rear Output Shaft Seal (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

1

Transfer Case Actuator Shaft Position Sensor O-Ring Seal

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

2

Transfer Case Actuator Shaft Position Sensor Assembly

3

Transfer Case Actuator Shaft Position Sensor Bolt/Screw

Tighten
9 N·m (80 lb in)

4

Transfer Case Two/Four Wheel Drive Actuator Assembly

5

Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw

Tighten
18 N·m (13 lb ft)

6

Transfer Case Oil Drain Plug

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

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)

7

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)

8

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.

9

Vehicle Speed Sensor O-Ring Seal

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

10

Vehicle Speed Sensor Assembly

Tighten
17 N·m (13 lb ft)

11

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 J 3289-20 holding fixture and remove the J 45759 assembly fixture from the transfer case.