Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure

1. Drain the transfer case fluid, if necessary. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
2. Remove the exhaust system. Refer to Exhaust System Replacement (Service and Repair).
3. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Rear Propeller Shaft Replacement)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Rear Propeller Shaft Replacement).




4. Support the transmission with a suitable screw jack and a block of wood.
5. Remove the transmission mount-to-body bolts.
6. Using the jack, lower the transmission enough to access the transmission mount-to-transfer case mounting bolts.




7. Remove the transmission mount-to-transmission case mounting bolts.
8. Remove the transmission mount assembly from the vehicle.
9. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).





Note: Do not remove the jack and block of wood from under the transmission.

10. Using another suitable adjustable jack, support the transfer case.
11. Remove the transfer case bolts.
12. Remove the transfer case.

Installation Procedure




1. Identify the version of transfer case to be installed. First design assemblies (1) have input shaft splines the full length of the shaft. Second design assemblies (2) have a machined inside diameter (ID) surface at the opening of the shaft. Refer to Build Variations within Transfer Case Description and Operation (Description and Operation) for additional information.




2. For first design AWD applications with 6 speed transmission, MYB with AWD designation MX7, install two O-rings onto the transmission output shaft prior to transfer case installation. Install the inner O-ring (1) onto the shaft to the end of the splines (2). Install the second O-ring until it contacts the first O-ring. Second design output shafts can be identified by the O-ring (3) located in the groove of the shaft. For second design applications, inspect the O-ring (3) for damage. Replace as required. Second design output shafts do not require installation of the two additional O-rings.




3. Apply grease GM P/N 1051344 (Canadian P/N 993037), or equivalent, on the input splines only. Start at the front edge of the splines and apply a continuous pattern around the ID to completely fill the splines from front to rear.
4. Install the transfer case.
Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the transfer case-to-transmission bolts and tighten to 60 Nm (44 lb ft).
6. Remove the adjustable jack from the transfer case.




7. Install the transmission mount assembly. Refer to Transmission Mount Replacement (Rear Wheel Drive) (Service and Repair)Transmission Mount Replacement (All Wheel Drive) (Service and Repair).
8. Remove the jack and block of wood from under the transmission.
9. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).
10. Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Rear Propeller Shaft Replacement)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Rear Propeller Shaft Replacement).
11. Install the exhaust system. Refer to Exhaust System Replacement (Service and Repair).
12. Refill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).