Disassembly Procedure

Tools Required 

• J 3289-20  Holding Fixture
• J 22912-01  Split Plate Bearing Puller
• J 23907  Slide Hammer with Bearing Adapter
• J 26941  Bushing and Bearing Remover - 3/4 inch
• J 36825  Output Shaft Oil Seal Remover - 4WD Models Only
• J 45358  Case Spreader
• J 45759  Assembly Fixture
• J 45849  Bearing Remover

1. Mount the J 3289-20  to a sturdy workbench.
2. Attach the J 45759  on the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759. 
   Fig 1: Installing J 45759 Using Adapter Studs

   Courtesy of GENERAL MOTORS CORP.
3. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.
   Fig 2: Installing J 45759 Into J 3289-20

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4. Remove the drain plug. Ensure all of the transfer case fluid is drained out of the transfer case.
   Fig 3: Removing Drain Plug

   Courtesy of GENERAL MOTORS CORP.
   NOTE: Refer to TRANSFER CASE SEAL REMOVAL NOTICE in Cautions and Notices.

   Important: 

   The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.

5. Remove the front input shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
6. Pry the inner seal race forward.
   Fig 4: Moving Front Input Shaft Inner Seal Race Forward

   Courtesy of GENERAL MOTORS CORP.
7. Using a small pry bar, move the inner seal race forward on the front input shaft.
8. Remove the inner seal race from the front input shaft.
   Fig 5: Removing Inner Seal Race From Front Input Shaft

   Courtesy of GENERAL MOTORS CORP.
9. Insert a flat-tipped screwdriver or a small pry bar between the lip of the outer lip of the front output shaft seal and the transfer case.
10. Remove the remaining part of the front output shaft seal from the transfer case.
    Fig 6: Removing Front Output Shaft Seal

    Courtesy of GENERAL MOTORS CORP.
11. Remove the vehicle speed sensor (VSS) with O-ring seal.
    Fig 7: Removing Vehicle Speed Sensor

    Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to TRANSFER CASE SEAL REMOVAL NOTICE in Cautions and Notices.
12. Remove the rear output shaft seal by prying out with a flat-bladed screwdriver.
    Fig 8: Removing Rear Output Shaft Seal

    Courtesy of GENERAL MOTORS CORP.
13. Remove the transfer case retaining bolts and the washers.
14. Mark the location of the brackets.
    Fig 9: Removing Transfer Case Retaining Bolts

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    NOTE: Refer to MACHINED SURFACE DAMAGE NOTICE in Cautions and Notices.
15. Using the J 45358  between the tabs on the case halves, shear the sealer holding the case halves together.
16. Using pry bars at each side of the case, remove the case from the locating pins.
    Fig 10: Identifying J 45358

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17. Remove the rear case half from the front case half. The rear output shaft will come out with the rear case half.
    Fig 11: Separating Rear Case Halves

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18. Remove the planetary carrier assembly thrust washer.
    Fig 12: Removing planetary carrier assembly thrust washer

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19. Remove the planetary carrier assembly.
    Fig 13: Removing Planetary Carrier Assembly

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20. Remove the sun gear thrust washer.
    Fig 14: Removing Sun Gear Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
21. Remove the front input shaft.
    Fig 15: Removing Front Input Shaft

    Courtesy of GENERAL MOTORS CORP.
22. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
    Fig 16: Removing Cup Plug In Front Output Shaft

    Courtesy of GENERAL MOTORS CORP.

    Important: 

    If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.

23. Remove the chain with the driven sprocket.
    Fig 17: Removing Chain With Driven Sprocket

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24. Remove the sun gear with the drive gear and viscous coupling. Lift up on the sun gear assembly while tapping down on the input shaft with a soft-faced hammer.
    Fig 18: Removing Sun Gear Assembly

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25. Using a hydraulic press and J 22912-O1  remove the bearing from the sun gear.
    Fig 19: View Of J 22912-O1

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26. Remove the drive gear from the sun gear.
    Fig 20: Removing Drive Gear From Sun Gear

    Courtesy of GENERAL MOTORS CORP.
27. Remove the viscous coupling from the sun gear.
    Fig 21: Removing Viscous Coupling

    Courtesy of GENERAL MOTORS CORP.
28. Remove the input shaft from the front case.
    Fig 22: Removing Input Shaft From Front Case

    Courtesy of GENERAL MOTORS CORP.
29. Using the J 23907  (1) and the J 36825  (2), remove the input seal.
    1. Poke a hole in the seal using a very sharp punch.
    2. Thread the J 36825  (2) into the hole.
    Fig 23: Removing Input Seal Using J 23907 & J 36825

    Courtesy of GENERAL MOTORS CORP.
30. Remove the input shaft bushing from the front case using a hammer and brass drift.
    Fig 24: Removing Input Shaft Bushing From Front Case

    Courtesy of GENERAL MOTORS CORP.
31. Using a brass drift, remove the front output shaft bearing from the front case half.
    Fig 25: Removing Front Output Shaft Bearing From Front Case Half

    Courtesy of GENERAL MOTORS CORP.
32. If necessary, remove the vent from the front case half.
    Fig 26: Removing Vent From Front Case Half

    Courtesy of GENERAL MOTORS CORP.

    Important: 

    Depending on the build date of the transfer case, it may have a rear output shaft bearing with or without a retaining ring groove. In early build transfer cases, the retaining ring (1) for the rear output shaft bearing was in front of the bearing (2). In later build transfer cases, the retaining ring (3) was moved rearward 5 mm (0.197 in) in the case. The bearings (4) have a groove and the retaining ring is installed in the groove.

33. Remove the rear output shaft from the rear case half.
    1. Spread the rear output shaft rear bearing outer retaining ring.
    2. Using a soft-faced hammer, tap on the end of the rear output shaft.
    Fig 27: Identifying Types Of Rear Output Shaft Bearing Retaining Rings

    Courtesy of GENERAL MOTORS CORP.
34. Remove the annulus gear retaining ring.
    Fig 28: Removing Annulus Gear Retaining Ring

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35. Remove the rear output shaft from the annulus gear.
    Fig 29: Removing Rear Output Shaft From Annulus Gear

    Courtesy of GENERAL MOTORS CORP.
36. Inspect the bearing in the rear output shaft. Refer to Cleaning and Inspection .
37. If the bearing is faulty, remove the bearing using the J 45849. 
    • Install the finger part of the J 45849  in the bearing.
    • Thread the driver part into the fingers.
    • Remove the bearing from the fingers by squeezing the fingers together.
    Fig 30: View Of J 45849

    Courtesy of GENERAL MOTORS CORP.
38. Remove the retaining ring for the rear output shaft bearing and the speed reluctor wheel.
    Fig 31: Removing Rear Output Shaft Bearing Retaining Ring & Speed Reluctor Wheel

    Courtesy of GENERAL MOTORS CORP.
39. Using a hydraulic press and the J 22912-O1  remove the speed reluctor wheel and the rear output shaft bearing

    Do not use the speed reluctor wheel again.

    Fig 32: Identifying J 22912-O1

    Courtesy of GENERAL MOTORS CORP.
40. Remove the rear bearing for the front output shaft from the rear case, using the J 26941  (1) and the J 23907  (2).
    Fig 33: Removing Front Output Shaft Rear Bearing Using J 26941 & J 23907

    Courtesy of GENERAL MOTORS CORP.