GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Chevy Suburban - 4WD 🢒 Preface 🢒 Cautions and Notices 🢒 Transfer Case Disassemble
Table 1: Transfer Case Holding Fixture Installation
Table 2: Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, Actuator Shaft Position Sensor, and Vehicle Speed Sensor Removal
Table 3: Rear Output Shaft Seal and Bushing Removal
Table 4: Transfer Case Rear Case Half Removal
Table 5: Oil Pump Suction Pipe and Actuator Shaft Gear Removal
Table 6: Shift Fork Assembly, Drive Chain, and Rear Output Shaft Assembly Removal
Table 7: Rear Output Shaft Assembly Disassemble
Table 8: Input Shaft and Planetary Assembly Removal
Table 9: Front Output Shaft Assembly Removal

Transfer Case Holding Fixture Installation
Object Number: 1849343 Size: MF

Transfer Case Holding Fixture Installation

Callout

Component Name

1

Transfer Case Nuts

Special Tools

J 45759 Assembly Fixture

2

Transfer Case

Special Tools

J 3289-20 Holding Fixture

3

Pivot Pin

Tip

    • Always secure with the pivot pin after rotating.
    • The transfer case can be rotated 360 degrees to facilitate repair.

Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, Actuator Shaft Position Sensor, and Vehicle Speed Sensor Removal
Object Number: 1849344 Size: MF

Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, Actuator Shaft Position Sensor, and Vehicle Speed Sensor Removal

Callout

Component Name

1

Transfer Case Actuator Shaft Position Sensor Bolt/Screw

2

Transfer Case Actuator Shaft Position Sensor Assembly

3

Transfer Case Actuator Shaft Position Sensor O-Ring Seal

4

Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw

5

Transfer Case Two/Four Wheel Drive Actuator Assembly

6

Transfer Case Oil Drain Plug

7

Transfer Case Oil Fill Plug

8

Transfer Case Vent

Tip
Remove ONLY if the vent pipe is damaged.

9

Vehicle Speed Sensor Assembly

10

Vehicle Speed Sensor O-Ring Seal

11

Transfer Case Access Hole Plugs (Qty: 2)

Rear Output Shaft Seal and Bushing Removal
Object Number: 1849345 Size: MF

Rear Output Shaft Seal and Bushing Removal

Callout

Component Name

1

Transfer Case Rear Output Shaft Seal

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.

2

Transfer Case Rear Output Shaft Bushing

Tip

    • Only remove the bushing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection.
    • 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.
    • Follow the steps below for use of the J 45380 .
        1. Install the finger section of the J 45380 in front of the bushing.
        2. Install the tube and forcing screw assembly into the finger section. Ensure the forcing screw is backed out.
        3. Using a wrench on the forcing screw, remove the bushing.

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

Transfer Case Rear Case Half Removal
Object Number: 1849346 Size: MF

Transfer Case Rear Case Half Removal

Callout

Component Name

1

Transfer Case Bolts (Qty: 17)

2

Transfer Case Bracket

3

Transfer Case Rear Case Half

Notice: Refer to Machined Surface Damage Notice in the Preface section.

Tip

    • Use opposing pry bars at casting bosses to spread the case.
    • Use snap ring pliers to release the transfer case rear output shaft outer retaining ring from the transfer case rear output shaft rear bearing assembly.

Oil Pump Suction Pipe and Actuator Shaft Gear Removal
Object Number: 1849347 Size: MF

Oil Pump Suction Pipe and Actuator Shaft Gear Removal

Callout

Component Name

1

Transfer Case Actuator Shaft Gear

2

Transfer Case Oil Pump Suction Pipe

3

Transfer Case Oil Pump Suction Pipe Seal

Shift Fork Assembly, Drive Chain, and Rear Output Shaft Assembly Removal
Object Number: 1849348 Size: MF

Shift Fork Assembly, Drive Chain, and Rear Output Shaft Assembly Removal

Callout

Component Name

1

Transfer Case Rear Output Shaft Assembly

Tip
Mount the assembly into a soft-jaw vice or holding fixture for disassembly.

2

Transfer Case High/Low Shift Fork Assembly

3

Transfer Case High/Low Clutch

4

Transfer Case Front Output Shaft Drive Chain Assembly

Rear Output Shaft Assembly Disassemble
Object Number: 1849349 Size: MF

Rear Output Shaft Assembly Disassemble

Callout

Component Name

1

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

2

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip
Use an arbor press or suitable puller to remove the bearing from the rear output shaft.

3

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

4

Transfer Case Rear Output Shaft Speed Reluctor Wheel

5

Transfer Case Oil Pump Assembly

6

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

7

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

8

Transfer Case Front Output Shaft Drive Sprocket

9

Transfer Case Four Wheel Drive Clutch Housing Retaining Ring

10

Transfer Case Four Wheel Drive Clutch Housing

11

Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly (Qty: 2)

Tip
Only remove the bearing if faulty. Refer to Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection.

12

Transfer Case Front Output Shaft Drive Sprocket Spacer - Front

13

Transfer Case Two/Four Wheel Drive Clutch Retaining Ring

14

Transfer Case Four Wheel Drive Clutch Shim

15

Transfer Case Four Wheel Drive Clutch Hub

16

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

17

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

18

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

19

Transfer Case Four Wheel Drive Clutch Pressure - Apply - Plate

20

Transfer Case Control Actuator Lever Washer

21

Transfer Case Control Actuator Lever Thrust Bearing Assembly

22

Transfer Case Control Actuator Lever Assembly

23

Transfer Case Control Actuator Lever Ball (Qty: 3)

24

Transfer Case Control Actuator Lever Bearing Assembly

25

Transfer Case Control Lever

26

Transfer Case Control Actuator Lever Thrust Bearing Assembly

27

Transfer Case Rear Output Shaft

Input Shaft and Planetary Assembly Removal
Object Number: 1849350 Size: MF

Input Shaft and Planetary Assembly Removal

Callout

Component Name

1

Transfer Case Input Shaft Seal

2

Transfer Case Input Shaft Bearing Outer Retaining Ring

Caution: Do not rotate the transfer case while the retaining ring is removed. Rotating the transfer case while the retaining ring is removed, may cause the input shaft/planetary assembly to fall from the transfer case, resulting in personal injury.

3

Transfer Case Input Shaft/Planetary Assembly

4

Transfer Case High/Low Planetary Carrier Retaining Ring

5

Transfer Case High/Low Locking Plate

6

Transfer Case Planetary Carrier Sun Gear Thrust Washer

7

Transfer Case Input Shaft

8

Transfer Case Input Shaft Pilot Bearing Assembly

Tip
Only remove the bearing if faulty. Refer to Front Output Shaft and Input Shaft Cleaning and Inspection.

9

Transfer Case Planetary Carrier Sun Gear Thrust Washer

10

Transfer Case High/Low Planetary Carrier Assembly

11

Transfer Case Input Shaft Inner Retaining Ring

12

Transfer Case Input Shaft Bearing Assembly

Front Output Shaft Assembly Removal
Object Number: 1849351 Size: MF

Front Output Shaft Assembly Removal

Callout

Component Name

1

Transfer Case Front Case Half

Tip
Place the front case half on an arbor press.

2

Transfer Case Front Output Shaft Assembly

Tip
Press the front output shaft assembly from the front case half using an arbor press or soft-face hammer.

3

Transfer Case Front Output Shaft Seal