Approximate Fluid Capacities

Specification
Application Metric English
Synthetic Lubricant - Transfer Case 0.8 liter 0.85 quart
Fastener Tightening Specifications
Specification
Application Metric English
Transfer Case Bracket-to-Engine Bolt - Hole 4 50 N·m 37 lb ft
Transfer Case Bracket-to-Engine Bolts - Holes 1, 2, and 3 23 N·m 17 lb ft
Transfer Case Bracket-to-Transfer Case Bolts - Holes 5 and 6 50 N·m 37 lb ft
Transfer Case Drain Plug 39 N·m 29 lb ft
Transfer Case Fill Plug 39 N·m 29 lb ft
Transfer Case Half Bolts (Qty: 12) 29 N·m 21 lb ft
Transfer Case Heat Shield Bolts (Qty: 3) 11 N·m 97 lb in
Transfer Case Rear Output Drive Gear Nut (Qty: 1) 235 N·m 173 lb ft
Transfer Case Rear Output Drive Shaft Housing Bolts (Qty: 6) 29 N·m 21 lb ft
Adhesives, Fluids, Lubricants, and Sealers
GM Part Number
Application Type of Material United States Canada
Transfer Case Fill Synthetic Lubricant 89021677 89021678
All-Wheel Drive Schematics
Transfer Case Disassembled View

(1) Transfer Case Drain Plug

(2) Transfer Case Fill Plug
(3) Transfer Case Input Shaft Seal - Left
(4) Transfer Case O-Ring Seal
(5) Transfer Case - Left
(6) Transfer Case Vent Assembly
(7) Transfer Case Half Locating Pin (Qty: 2)
(7) Transfer Case Half Locating Pin (Qty: 2)
(9) Half Shaft Retainer
(10) Front Wheel Drive Retainer
(11) O-Ring
(12) Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
(12) Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
(13) Front Wheel Drive Intermediate Shaft Bearing Assembly
(14) Front Wheel Drive Intermediate Shaft
(15) Transfer Case Mounting Bracket Bolt (Qty: 6)
(16) Transfer Case Mounting Bracket
(17) Transfer Case Heat Shield Bolt (Qty: 3)
( ) (Q y )
(20) Transfer Case - Right
(21) Transfer Case Seal
(22) Transfer Case Input Shaft Seal - Right
(23) Front Drive Axle Intermediate Shaft Seal Assembly
(24) Transfer Case Input Shaft
(25) Transfer Case Rear Output Drive Shaft
(26) Transfer Case Rear Output Shaft Nut
(27) Transfer Case Rear Output Shaft Flange
(28) Transfer Case Rear Output Shaft Oil Slinger
(29) Transfer Case Rear Output Shaft Seal
(30) Transfer Case Rear Output Shaft Bearing Assembly (Qty: 2)
(30) Transfer Case Rear Output Shaft Bearing Assembly (Qty: 2)
(31) Transfer Case Rear Output Shaft Housing
(32) Transfer Case Rear Output Shim
(33) Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
(34) Transfer Case Rear Output Shaft Bearing Spacer
(35) Transfer Case Rear Output Shaft
(36) Transfer Case Rear Output Shaft Housing Seal O-Ring
Transfer Case Fluid Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

2. Remove the drain plug (2).

3. Remove the fill plug (1).

Installation Procedure
1. Clean the drain plug.

Caution: Refer to Component Fastener Tightening Caution in the Preface section.

2. Install the drain plug (2) and tighten to 39 N·m (29 lb ft).
3. Fill the transfer case with synthetic gear lubricant GM P/N 89021677
(Canadian P/N 89021678) to the bottom of the fill plug, or 0.80 L (0.85 qt).
4. Install the fill plug (1) and tighten to 39 N·m (29 lb ft).
5. Lower the vehicle.
Transfer Case Brace Replacement (LZ4 Transfer Case to
Engine Oil Pan)

Callout Component Name

Preliminary Procedure
Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
Transfer Case Brace Bolt (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

1

Tighten
50 N·m (37 lb ft)
2 Transfer Case Brace
Transfer Case Brace Replacement (LZ4 Transfer Case to
Engine Block)

Callout Component Name

Preliminary Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
Transfer Case Brace Bolt (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

1 Tip
Tighten the fasteners in the specified sequential order.

Tighten
23 N·m (17 lb ft)

Transfer Case Brace Bolt (Qty: 2)

2
Tip
Tighten the fasteners in the Motors
© 2010 General specified sequential
Corporation. order.
All rights reserved.
 ( )
Transfer Case Brace Stud

Tip
3 Tighten the fasteners in the specified sequential order.

Tighten
50 N·m (37 lb ft)
4 Transfer Case Brace
Transfer Case Brace Replacement (LY7)

Callout Component Name

Preliminary Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
Transfer Case Brace Bolt (Qty: 2)

Caution: Refer to Fastener Caution in the Preface section.

1 Tip
Tighten the fasteners in the specified sequential order.

Tighten
50 N·m (37 lb ft)

Transfer Case Brace Bolt

2 Tip
Tighten the fasteners in the specified sequential order.

Tighten
 Transfer Case Brace Bolt (Qty: 3)

Tip
3 Tighten the fasteners in the specified sequential order.

Tighten
23 N·m (17 lb ft)
4 Transfer Case Brace
Transfer Case Assembly Replacement (LZ4)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement.
3. Remove the propeller shaft. Refer to Propeller Shaft Replacement.
4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and
Catalytic Converter Replacement - Left Side.

6. Remove the transfer case mounting bracket bolts (1).

7. Remove the transfer case mounting bracket (2).
 8. Remove the transfer case mounting bracket bolts (1, 3) and stud (2).
9. Remove the transfer case mounting bracket (4).
10. Support the transaxle with a jackstand.
11. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket
Replacement - Rear.

12. Remove the bolts (1) securing the transfer case to the transaxle.
13. Remove the transfer case (2) from the transaxle.

14. If replacing the transfer case, complete the following steps.

• Remove the transfer case heat shield bolts (1).
• Remove the transfer case heat shield (2).
 Caution: Refer to Fastener Caution in the Preface section.

1. If the transfer case heat shield was previously removed, complete the following steps.
• Install the transfer case heat shield (2).
• Install the transfer case heat shield bolts (1) and tighten to 10 N·m (89 lb in).

2. Install the transfer case (2) from the transaxle.

3. Install the bolts (1) securing the transfer case to the transaxle. Tighten the bolts to 50 N·m
(37 lb ft).
 5. Remove the jackstand supporting the transaxle.

Note: Tighten the bolts in the specified sequential order.

6. Install the transfer case mounting bracket (4).

7. Install the transfer case mounting bracket bolts (1) and stud (2) and tighten the bolts/studs
in specified sequential order to 50 N·m (37 lb ft).
8. Install the transfer case mounting bracket bolt (3) and tighten to 23 N·m (17 lb ft).

9. Install the transfer case mounting bracket (2).

10. Install the transfer case mounting bracket bolts (1) and tighten to 50 N·m (37 lb ft).
12. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
13. Install the propeller shaft. Refer to Propeller Shaft Replacement.
14. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement.
15. Lower the vehicle.
Transfer Case Assembly Replacement (LY7)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement.
3. Remove the propeller shaft. Refer to Propeller Shaft Replacement.
4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and
Catalytic Converter Replacement - Left Side.

6. Remove the transfer case mounting bracket bolts (1, 2, 4).

7. Remove the transfer case mounting bracket (3).
8. Support the transaxle with a jackstand.
9. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket
Replacement - Rear.
10. Remove the bolts (1) securing the transfer case to the transaxle.
11. Remove the transfer case (2) from the transaxle.

12. If replacing the transfer case, complete the following steps.

• Remove the transfer case heat shield bolts (1).
• Remove the transfer case heat shield (2).

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.
1. If the transfer case heat shield was previously removed, complete the following steps.
• Install the transfer case heat shield (2).
• Install the transfer case heat shield bolts (1) and tighten to 10 N·m (89 lb in).

2. Install the transfer case (2) from the transaxle.

3. Install the bolts (1) securing the transfer case to the transaxle and tighten the bolts to
50 N·m (37 lb ft).
4. Install the rear transmission mount and bracket. Refer to Transmission Mount Bracket
Replacement - Rear.
5. Remove the jackstand supporting the transaxle.

Note: Tighten the bolts in the specified sequential order.

 6. Install the transfer case mounting bracket (3).
7. Install the transfer case mounting bracket bolts (1) and tighten to 23 N·m (17 lb ft).
8. Install the transfer case mounting bracket bolt (4) and tighten to 50 N·m (37 lb ft).
9. Install the transfer case mounting bracket bolt (2) and tighten to 50 N·m (37 lb ft).
10. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and
Catalytic Converter Replacement - Left Side.
11. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.
12. Install the propeller shaft. Refer to Propeller Shaft Replacement.
13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement.
14. Lower the vehicle.
Transfer Case Disassemble
Table 1: Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Table 2: Intermediate Drive Shaft Removal
Table 3: Rear Output Shaft Housing Removal
Table 4: Right Transfer Case, Input and Output Drive Shaft Removal
Table 5: Rear Output Shaft Housing Disassembly
Table 6: Intermediate Drive Shaft Disassembly

Housing O-Ring, Vent Assembly, Drain and Fill Plug

Removal

Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal

Callout Component Name
1 Transfer Case O-Ring Seal
Transfer Case Vent Assembly
2
Tip
Remove the vent only if damaged or blocked.
3 Transfer Case Bracket Bolts (Qty: 6)
 5 Transfer Case Heat Shield Bolts (Qty: 3)
6 Transfer Case Heat Shield
7 Transfer Case Drain Plug
8 Transfer Case Fill Plug

Intermediate Drive Shaft Removal

Intermediate Drive Shaft Removal

Callout Component Name
1 Front Wheel Drive Retainer
Front Wheel Drive Intermediate Shaft

2 Special Tools
J 25070 Heat Gun - 500-750F

Rear Output Shaft Housing Removal

Rear Output Shaft Housing Removal
Callout Component Name
1 Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
Transfer Case Rear Output Shaft Housing

Tip
Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal.
2

Special Tools
J 25070 Heat Gun - 500-750F
3 Transfer Case Rear Output Shim
Transfer Case Rear Output Shaft Housing Seal O-Ring
4
Tip
Discard the O-ring after removal.

Right Transfer Case, Input and Output Drive Shaft

Removal
Right Transfer Case, Input and Output Drive Shaft Removal
Callout Component Name
1 Transfer Case Half Bolts (Qty: 12)
2 Transfer Case - Right
3 Transfer Case Seal
4 Transfer Case Input Shaft
5 Transfer Case Rear Output Drive Shaft
Transfer Case Half Locating Pins (Qty: 2)

Tip
6 • Remove the pins only if damaged.
• Inspect the case for similar damage.

Refer to Transfer Case Cleaning and Inspection.

Rear Output Shaft Housing Disassembly

Rear Output Shaft Housing Disassembly
Callout Component Name
Transfer Case Rear Output Drive Gear Nut

Tip
Use a 30 mm socket or J 29873 .
1

Special Tools
J-08614-A Pinion Flange Holder and Remover
Transfer Case Rear Output Shaft Flange

2 Special Tools
DT-48146 Press Support
Transfer Case Rear Output Shaft Bearing Assembly
3
Tip
Use a press to remove the output shaft from the housing.
4 Transfer Case Rear Output Shaft Bearing Spacer
5 Transfer Case Rear Output Shaft
Transfer Case Rear Output Shaft Oil Slinger
6
Tip
 Refer to Rear Output Drive Housing Cleaning and Inspection.
Transfer Case Rear Output Shaft Seal
7
Tip
Discard the seal after removal.

Intermediate Drive Shaft Disassembly

Intermediate Drive Shaft Disassembly

Callout Component Name
1 Half Shaft Retainer
2 O-Ring
3 Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)
Front Wheel Drive Intermediate Shaft Bearing Assembly

Tip
Use a press, with the J 22912-B flat side up, in order to remove the bearing
4 assembly.

Special Tools
Transfer Case Cleaning and Inspection

Callout Component Name

Caution: Refer to Machined Surface Damage Caution in the Preface section.

Preliminary Procedure
1. Inspect all components or sub-components and perform any repair procedure
necessary to fix the damage. If the damage cannot be repaired, replace the
component or sub-component as indicated.
2. Clean the left and right transfer case in cleaning solvent and air dry.
Transfer Case - Left and Right

1 Tip
Inspect for cracks, broken areas, or other damage. The transfer case assembly
must be replaced if damage is found.
Transfer Case Rear Output Drive Housing Bore
2
Tip
Repair small scratches or nicks with light sanding.
Case Sealing Surface
3
 p
Transfer Case Bearing Races
4
Tip
Replace the transfer case assembly if a bearing has spun or if cracks are detected.
Transfer Case Thread Bolt Holes
5
Tip
Repair any damaged threads.
6 Transfer Case Half Locating Pin Holes
Rear Output Drive Housing Cleaning and Inspection

Callout Component Name

Preliminary Procedures
1. Inspect all components or sub-components and perform any repair procedure
necessary to fix the damage. If the damage cannot be repaired, replace the
component or sub-component as indicated.
2. Clean all components in cleaning solvent and air dry.
3. The transfer case rear output drive housing is not serviced. If damage cannot be
repaired, the transfer case must be replaced.
Transfer Case Rear Output Shaft Flange

1 Tip
• Replace if flange, threaded holes, or splines are damaged.
• Inspect sealing surface for corrosion, excessive wear, or damage.
Transfer Case Rear Output Shaft Oil Slinger
2
Tip
Replace the slinger if damaged, cracked, loose, or distorted.
Transfer Case Rear Output Shaft Bearing Assembly
 p g g p g p g
Transfer Case Rear Output Shaft Housing

Tip
• Inspect for cracks, broken areas, or other damage.
4
• Inspect bearing races for roughness, brinelling, or pitting.
• Inspect the O-ring channel for porosity or damage.
• Scratches or nicks in other areas may be repaired with light sanding.
Transfer Case Rear Output Shaft Splines
5
Tip
Inspect for damage and press fit to flange.
Transfer Case Rear Output Shaft
6
Tip
Inspect for pitting, excessive wear, or damage.
Input Shaft Seal Replacement - Right

Callout Component Name

Transfer Case Input Shaft Seal - Right

Caution: Do not use a screwdriver or punch to remove the seal. Using a

screwdriver or punch to remove the seal may damage the aluminum housing
sealing surface.

1 Special Tools

• DT-48074 Input and Output Shaft Seal Installer

• J-8092 Driver Handle
• J-26941 Bushing and Bearing Remover - 3-4 in
• J-45124 Removal Bridge
Input Shaft Seal Replacement - Left

Callout Component Name

Transfer Case Input Shaft Seal - Left

Caution: Do not use a screwdriver or punch to remove the seal. Using a

screwdriver or punch to remove the seal may damage the aluminum housing
sealing surface.

1 Special Tools

• DT-48074 Input and Output Shaft Seal Installer

• J-8092 Driver Handle
• J-26941 Bushing and Bearing Remover - 3-4 in
• J-45124 Removal Bridge
Front Drive Axle Inner Shaft Seal Replacement

Callout Component Name

Front Drive Axle Intermediate Shaft Seal Assembly

Tip
DT-48078 seats the seal to a specific depth. Other installation methods may set the
seal to a non-functional depth.
1
Special Tools

• DT-48078 Inner Drive Shaft Seal Installer

• J 8092 Driver Handle
Input Shaft and Rear Output Drive Shaft Cleaning and
Inspection

Callout Component Name

Preliminary Procedures
1. Inspect all components or sub-components and perform any repair procedure
necessary to fix the damage. If the damage cannot be repaired, replace the
component or sub-component as indicated.
2. Clean all components in cleaning solvent and air dry.
3. The transfer case input shaft and transfer case rear output drive shaft is not serviced.
If damage cannot be repaired, the transfer case must be replaced.
Transfer Case Input Shaft Gear
1
Tip
Inspect for pitting, excessive wear, or damage.
Transfer Case Rear Output Drive Shaft Gear
2
Tip
Inspect for pitting, excessive wear, or damage.
Transfer Case Input Shaft Bearing Assembly
 p g g p g p g
Transfer Case Rear Output Drive Shaft Bearing Assembly
4
Tip
Inspect bearings for roughness, spalling, or pitting.
Transfer Case Assemble
Table 1: Intermediate Drive Shaft Assembly
Table 2: Rear Output Shaft Housing Assembly
Table 3: Output Flange Installation
Table 4: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
Table 5: Rear Output Shaft Housing Installation
Table 6: Intermediate Drive Shaft Installation
Table 7: Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation

Intermediate Drive Shaft Assembly

Intermediate Drive Shaft Assembly

Callout Component Name
1 Front Wheel Drive Intermediate Shaft
2 Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)
Front Wheel Drive Intermediate Shaft Bearing Assembly

Tip
Use a press, with the J-22912-B Rear Pinion and Axle Bearing Remover flat side up,
 3 Special Tools
J-22912-B Rear Pinion and Axle Bearing Remover
4 O-Ring
5 Half Shaft Retainer

Rear Output Shaft Housing Assembly

Rear Output Shaft Housing Assembly

Callout Component Name
1 Transfer Case Rear Output Shaft
2 Transfer Case Rear Output Shaft Bearing Spacer
3 Transfer Case Rear Output Shaft Housing
Transfer Case Rear Output Shaft Bearing Assembly

Tip
Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the
4
housing and bearings to the output shaft.

Special Tools
 Transfer Case Rear Output Shaft Seal

Tip
Use a press with the DT-48075 Output Shaft Seal Installer to install the seal.
5

Special Tools
DT-48075 Output Shaft Seal Installer

Output Flange Installation

Output Flange Installation

Callout Component Name
Transfer Case Rear Output Shaft Oil Slinger

Tip
Use a press with the DT-48077 Output Shaft Slinger Installer in order to install the
1 slinger.

Special Tools
DT-48077 Output Shaft Slinger Installer
 Tip
Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the
2 flange.

Special Tools
J-5590 Pinion Bearing Race Installer - Rear
Transfer Case Rear Output Shaft Nut

Caution: Refer to Fastener Caution in the Preface section.

Tip
Use a 30 mm socket or the J-29873 Injector Nozzle Socket 30 mm and the J-
08614-A Pinion Flange Holder and Remover .

3
Tighten
235 N·m (173 lb ft)

Special Tools

• J-08614-A Pinion Flange Holder and Remover

• J-29873 Injector Nozzle Socket 30 mm

Right Transfer Case, Input Shaft, and Output Drive

Shaft Installation
Right Transfer Case, Input Shaft, and Output Drive Shaft
Installation
Callout Component Name
1 Transfer Case Half Locating Pins
2 Transfer Case Rear Output Drive Shaft
Transfer Case Input Shaft
3
Tip
Install the input and output shafts as a set with the splines engaged.
4 Transfer Case Seal
5 Transfer Case - Right
Transfer Case Half Bolts (Qty: 12)

Caution: Refer to Fastener Caution in the Preface section.

6

Tighten
29 N·m (21 lb ft)

Rear Output Shaft Housing Installation

Rear Output Shaft Housing Installation
Callout Component Name
1 Transfer Case Rear Output Shaft Housing Seal O-Ring
2 Transfer Case Rear Output Shim
Transfer Case Rear Output Shaft Housing

Caution: Do not use a drive hammer when the splines are not engaged. Use of a
drive hammer when the splines are not engaged will damage the output shaft teeth.

Tip
3 • Use of a heat gun allows easy alignment of the bolt holes to the housing
during assembly.
• Rotate the pinion gear during assembly to engage the gear teeth.

Special Tools
J-25070 Heat Gun - 500-750F
Transfer Case Rear Output Shaft Housing Bolts (Qty: 6)

Caution: Refer to Fastener Caution in the Preface section.

4

Tighten
29 N·m (21 lb ft)
Intermediate Drive Shaft Installation
Callout Component Name
Front Wheel Drive Intermediate Shaft

Caution: DT-48094 must be used over the intermediate shaft prior to installation in
order to protect the intermediate shaft seal from damage.

1
Special Tools

• DT-48094 Inner Drive Shaft Seal Protector

• J-25070 Heat Gun - 500-750F
2 Front Wheel Drive Retainer

Housing O-Ring, Vent Assembly, Drain and Fill Plug

Installation
Housing O-Ring, Vent Assembly, Drain and Fill Plug
Installation
Callout Component Name
1 Transfer Case O-Ring Seal
Transfer Case Vent Assembly
2
Tip
Replace the vent if damaged or blocked.
Drain Plug

Caution: Refer to Component Fastener Tightening Caution in the Preface section.

3

Tighten
39 N·m (29 lb ft)
Fill Plug
4
Tighten
39 N·m (29 lb ft)
5 Transfer Case Heat Shield
Transfer Case Heat Shield Bolts (Qty: 3)

Caution: Refer to Fastener Caution in the Preface section.

6

Tighten
11 N·m (97 lb in)
 Transfer Case Bracket Bolts (Qty: 2)

8 Tip
Tighten the bracket bolts to light assembly torque. Tighten to specification after the
transfer case is mounted in the vehicle. Refer to Fastener Tightening Specifications.