Transfer Case Cleaning - Fiber Material from Transmission into Transfer Case

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Pontiac Aztek, 2003 Oldsmobile Silhouette, 2003 Chevrolet Venture, and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Important:

Transmission oil circulates between the transmission assembly and the transfer case differential carrier and three helical gear set. In situations where transmission related failures circulate fiber type debris, such as clutch friction disc material into the transfer case, the helical gear portion of the transfer case must be disassembled, cleaned and inspected for damage. In situations where transmission or transfer case related failures circulate metal type debris, such as bearing material, repair or overhaul of both components may be required.

Install the transfer case assembly (1) onto the J 44755 (3). Position the carrier onto the post of the fixture.
Install the retaining bolts (2).
Tighten

Tighten the bolts to 50 N.m (37 lb ft).
Remove the speed sensor (1).

Fig 1: Removing Speed Sensor
Courtesy of GENERAL MOTORS CORP.
Remove the bolts (1) from the case.

Fig 2: Removing Bolts
Courtesy of GENERAL MOTORS CORP.
Separate the case-right (2) from the case-left (1).

Fig 3: Separating Case-Right From Case-Left
Courtesy of GENERAL MOTORS CORP.
Clean the case-left and driveshaft gear (1) in solvent. Inspect for fiber or metal type debris within the unit and repair as required.

Fig 4: Cleaning Driveshaft Gear And Case Left
Courtesy of GENERAL MOTORS CORP.
Clean the case-right and idler gear (1) in solvent. Inspect for fiber or metal type debris within the unit and repair as required.

Fig 5: Installing Idler Gear To Case-Right
Courtesy of GENERAL MOTORS CORP.
Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the sealing surface of the case-right.
Install the idler gear (1) to the case-right.
Install the idler gear into the case-right. The side of the gear with the long flange area (1) should be installed to the case-right.

Fig 6: Identifying Flange Area Of Idler Gear
Courtesy of GENERAL MOTORS CORP.
Install the case-right (2) to the case-left (1).

Fig 7: Installing Case-Right To Case-Left
Courtesy of GENERAL MOTORS CORP.
Install the bolts (1) to the case.

Fig 8: Installing Bolts To Case
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the bolts to 60 N.m (44 lb ft).
Install the speed sensor (1) and O-ring.

Fig 9: Installing Speed Sensor And O-Ring
Courtesy of GENERAL MOTORS CORP.