New Product Information
New Product Information
The purpose of New Product Information is to document, important product changes which occur either model year-to-model year or interim model year.
Changes may include one or more of the following items:
* Specification Changes
* New sealants and/or adhesives
* Disassembly and assembly procedure revisions
* Mechanical and diagnostic procedure revisions
* New special tools required
* Interim model year design changes
* A component comparison from the previous model year
Interim Model Year Design Change - NQF/NQG/NQH/NPO Front Output Shaft, Deflector, Seal
Interim 2011 model year, a new design front output shaft deflector (3) was implemented into production for second design NQF and NQG applications. First design 2011 model year NQF and NQG applications can be identified as not having the deflector on the front output shaft.
For service, the new design front output shaft, deflector, and new design seal may be installed on current and prior model year Magna NQF, NQG, NQH, and NP0 applications providing the new design front output shaft is also installed. The front output shaft deflector is to be installed using J 8092 - driver handle (1) and DT 50649 - seal installer (2).
The new design deflector (1) can be installed onto all current and prior model year Magna RPOs NQF, NQG, NQH, and NPO applications providing the new design front output shaft (2) is also installed. Second design front output shafts can be identified by the machined area on the OD output end of the shaft (2). First design front output shafts can be identified by the dust boot clamp groove located (3) at the OD output end of the shaft. The new design slinger will NOT install onto the first design shafts.
Service Parts Release Usage Change - NQH/NPO Control Actuator Levers
Light Duty (LD) 2007-2010 MP3023-NQH and 2010 MP3010-NP0 production transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5)
Heavy duty (HD) 2007-10 MP3024-NQH production transfer cases are built with HD control actuator levers (3 and 6) and are used with Heavy 10 mm (0.39 in) control actuator lever balls.
When replacement of one or both of the LD control actuator levers is required, it is necessary to replace both of the levers and all three balls with the HD components as a set. It is also necessary to re-measure and adjust clutch pack clearances as required and to perform the Transfer Case High/Low Clutch Reset. Refer to Measuring/Adjusting Clutch Assembly Height in Transfer Case Assemble, Transfer Case Description and Operation and Transfer Case High/Low Clutch Reset. Heavy duty (HD) components are the only parts available for service.
Interim Model Year Design Change - NQG High/Low Shift Fork, Fork Pad, and High/Low Clutch
Interim 2012 model year the High/Low shift fork, fork pad, and High/Low clutch design changed. The first design forks (2) can be identified as having three flat un-notched fork pad areas with three separate fork pads (1). The second design forks (4) can be identified as having a half-round shaped pad area with three notches for pad orientation and installation and upper and lower half-round fork pads (3). The second design shift fork (4) and pads (3) are the only design available for service and must be used with the second design High/Low clutch.
Interim 2012 model year the High/Low shift fork, fork pad, and High/Low clutch design changed. The first design high/low clutch (1) can be identified by having a 73 mm (2.87 in) OD rear flange (2). The second design high/low clutch (3) can be identified by having a 76 mm (2.99 in) OD rear flange (4).
For service:
* The first design 73 mm (2.87in) high/low clutch may NOT be used with the second design fork and pad.
* The second design 76 mm (2.99in) high/low clutch must be used with the second design fork and fork pad.
* The second design 76 mm (2.99in) high/low clutch may also be used with the first design fork and pad if first design fork replacement is not required.
Interim Model Year Design Change - NQF/NQG/NQH Front Case Half Assembly, Input Shaft, Planetary Carrier High/Low Clutch
Interim 2012 model year for Magna transfer case RPOs NQF / NQG / NQH, a second-design front case half assembly (1), planetary internal gear (2), gear retaining ring (3), locking plate (4), thrust washer (5), input shaft (6), pilot bearing (7), thrust washer (8), high/low planetary carrier (9), and high/low clutch (10) were implemented into second-design assemblies.
The second-design carrier (9) has a reduced OD dimension and the planetary internal gear (2) has a reduced ID dimension. The planetary internal gear (2) is a press-fit non-serviceable component and must be serviced with the front case half assembly. In service it is possible that a new or remanufactured transfer case may contain first or second-design content. For service, the first-design 2007-2012 Magna NQF, NQG, and NQH components will remain available individually to perform a repair on a first-design assembly.
If a second-design transfer case has been installed into a vehicle that originally contained a first-design assembly, TCCM reprogramming is not required.
Production Assembly Breakpoints
The design level and component content of the transfer case can be determined by referencing the assembly part number located on the identification label.
Magna Transfer Case Bar Code Label
1 - Component Identifier
2 - GM Broadcast Code
3 - Supplier Code
4 - Production Year
5 - Julian Date of the Year
6 - Assembly Line Number
7 - Sequential Number
8 - GM Assembly Part Number
Front Case Half
The first design front case half assembly can be identified as having an internal gear that is a 94 tooth design with an inside diameter (a) of 148.5 mm (5.85 in).
The second design front case half assembly can be identified as having an internal gear that is a 91 tooth design with an inside diameter (a) of 142 mm (5.59 in).
Input Shaft
The first design input shaft can be identified as a 56 tooth design with an outside diameter (a) of 91.4 mm (3.60 in).
The second design input shaft can be identified as a 53 tooth design with an outside diameter (a) of 87.50 mm (3.44 in).
High/Low Planetary Carrier Assembly
The first design light duty 3-pinion (1) and heavy duty 5-pinion (2) high/low planetary carriers can be identified as having a 30 tooth design with an inside diameter (a or b) of 61.3 mm (2.41 in).
The second design light duty 3-pinion (4) and heavy duty 6-pinion (3) high/low planetary carriers can be identified as having a 29 tooth design with an inside diameter (c or d) of 60.2 mm (2.37 in).
High/Low Clutch
The first design high/low clutch can be identified as having a 30 tooth design with a gear tooth outside diameter (a) of 65.50 mm (2.58 in).
The second design high/low clutch can be identified as having a 29 OD tooth design with a gear tooth outside diameter (a) of 63.25 mm (2.49 in).
Component Replacement - Conversion from First Design to Second Design
It is possible to repair a first-design assembly using second-design components.
When servicing a first-design assembly with second-design components, the following components MUST be replaced as a group:
1. Front Case Half Assembly - with internal gear and retaining ring
2. Locking Plate
3. Thrust Washer (front)
4. Input Shaft
5. Pilot Bearing
6. Thrust Washer (rear)
7. Planetary Carrier Assembly
8. High/Low Clutch