Disassembly Procedure

Remove the No.1 plug from the transfer case assembly.

Fig 1: Identifying No.1 Plug From Transfer Case Assembly
Courtesy of GENERAL MOTORS CORP.
Remove the No.2 plug from the transfer case assembly.
Place a drain pan under the transfer case.

Fig 2: Locating No.2 Plug From Transfer Case Assembly
Courtesy of GENERAL MOTORS CORP.
Remove the drain plug from the transfer case assembly.
Remove the breather plug from the transfer case assembly.

Fig 3: View Of Drain Plug
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Remove the transfer case cover bolts.

Fig 4: Locating Transfer Case Cover Bolts
Courtesy of GENERAL MOTORS CORP.
Using a brass drift and a hammer, remove the transfer case cover from the case.

Fig 5: Removing Transfer Case Cover From Case
Courtesy of GENERAL MOTORS CORP.
Remove the 3 transfer case mount bolts.
Remove the mount from the extension housing.
Remove the 4 alignment pins from the transfer case.

Fig 6: Locating Transfer Case Mount Bolts
Courtesy of GENERAL MOTORS CORP.
Using a soft faced hammer, remove the extension housing dust deflector.

Fig 7: Removing Extension Housing Dust Deflector
Courtesy of GENERAL MOTORS CORP.
Remove the oil seal from the extension housing.

Fig 8: Removing Oil Seal From Extension Housing
Courtesy of GENERAL MOTORS CORP.
Remove the 4 extension housing retaining bolts.
Remove the extension housing from the transfer case.

Fig 9: Removing Extension Housing Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
Using J 46003 and a torque wrench, measure the preload of the backlash between the drive pinion and the ring gear.
Preload

Ring gear and drive pinion preload at starting should be 0.32-0.57 N.m (2.8-5.0 lb in).

Total preload at starting should be 0.53-0.94 N.m (4.7-8.3 lb in).

Fig 10: Measuring Preload Of Backlash Between Drive Pinion & Ring Gear
Courtesy of GENERAL MOTORS CORP.
Using a dial indicator, check the backlash of the ring gear.
Important:

Backlash should be checked in 3 different positions on the ring gear.

Backlash

Backlash should be 0.10-0.15 mm

(0.0039-0.0059 in).

Fig 11: Checking Backlash Of Ring Gear With Dial Indicator
Courtesy of GENERAL MOTORS CORP.
Coat the teeth of the ring gear with Gear Marking Compound GM P/N 1052351
(Canadian P/N 10953497).
Rotate the ring gear.
Inspect the ring gear contact pattern.

Fig 12: Applying Gear Marking Compound To Teeth Of Ring Gear
Courtesy of GENERAL MOTORS CORP.
Remove the left transfer case oil seal.

Fig 13: Removing Left Transfer Case Oil Seal
Courtesy of GENERAL MOTORS CORP.
Remove the right transfer case oil seal.
Remove the bearing cap bolts and bearing cap from the ring gear assembly.

Fig 14: Removing Right Transfer Case Oil Seal
Courtesy of GENERAL MOTORS CORP.
Remove the output shaft spacer from the ring gear mounting case.
Remove the ring gear mounting case washer.
Remove the ring gear mounting case from the transfer case.

Fig 15: Removing Ring Gear Mounting Case
Courtesy of GENERAL MOTORS CORP.
Using a punch and a hammer, unstake the drive pinion nut.

Fig 16: Unstaking Drive Pinion Nut
Courtesy of GENERAL MOTORS CORP.
Using J 46003 and J 46001 remove the drive pinion retaining nut.

Fig 17: Removing Drive Pinion Nut Using J 46003 & J 46001
Courtesy of GENERAL MOTORS CORP.
Using a press, remove the drive pinion, spacer and washer from the transfer case.

Fig 18: Exploded View Of Drive Pinion, Spacer & Washer
Courtesy of GENERAL MOTORS CORP.
Using a press, remove the drive pinion bearing from the drive pinion.
Using a brass bar and a hammer, remove the drive pinion bearing race from the transfer case.
Using a press, remove the left and right ring gear mounting case bearings.

Fig 19: Removing Drive Pinion Bearing
Courtesy of GENERAL MOTORS CORP.
Using a brass bar and hammer, remove the left outer race from the transfer case.
Using a brass bar and hammer, remove the right outer race from the transfer case.

Fig 20: Removing Left & Right Outer Race From Transfer Case
Courtesy of GENERAL MOTORS CORP.
Using a dial indicator, check the runout of the ring gear.
Runout

Runout should not exceed 0.06 mm (0.0024 in).

Fig 21: Checking Runout Of Ring Gear With Dial Indicator
Courtesy of GENERAL MOTORS CORP.
Place alignment marks (1) on the ring gear and the mounting case.
Remove the 10 ring gear bolts.

Fig 22: Placing Alignment Marks On Ring Gear & Mounting Case
Courtesy of GENERAL MOTORS CORP.
Using a soft faced hammer, tap on the ring gear to separate it from the ring gear mounting case.

Fig 23: Separating Ring Gear From Ring Gear Mounting Case
Courtesy of GENERAL MOTORS CORP.
Using a dial indicator, check the runout of the ring gear mounting case.
Runout

Runout should not exceed 0.14 mm (0.0055 in).

Fig 24: Checking Runout Using Dial Indicator
Courtesy of GENERAL MOTORS CORP.
Using a brass bar and hammer, remove the drive pinion bearing race from the transfer case.

Fig 25: Removing Drive Pinion Bearing Race
Courtesy of GENERAL MOTORS CORP.