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Home › Hummer › 2009 › H3 Base, Automatic › Repair and Diagnosis › Transmission › Transfer Case › Repair Instructions - Off Vehicle › Transfer Case Disassemble › Disassemble

Transfer Case Disassemble: Disassemble

    Fig 1: Identifying J 45759
    GM1549462Courtesy of GENERAL MOTORS CORP.
  1. Using the adapter studs, attach the J 45759:  fixture to the transfer case. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759:  fixture.
    2. Fig 2: J 3289-20 Mounted To Workbench
    GM1549463Courtesy of GENERAL MOTORS CORP.
  2. Mount the J 3289-20:  fixture (1) to a sturdy workbench.
  3. Install the J 45759:  fixture (2) into J 3289-20:  fixture (1) and secure with pivot pin.
    4. Fig 3: Locating Drain Plug And The Fill Plug
    GM1549464Courtesy of GENERAL MOTORS CORP.
  4. Remove the drain plug and the fill plug. Ensure all transfer case fluid is drained out of the transfer case.
    5. Fig 4: Locating Encoder Motor, Bracket Bolts And Mounting Bolts
    GM1549473Courtesy of GENERAL MOTORS CORP.
  5. Remove the encoder motor bracket bolt (2).
  6. Remove the encoder motor mounting bolts (1).
  7. Remove the encoder motor assembly (3).
    8. Fig 5: View Of Vehicle Speed Sensor (VSS) & O-Ring Seal
    GM819577Courtesy of GENERAL MOTORS CORP.
  8. Remove the rear vehicle speed sensor (VSS) and the O-ring seal.
    9. Fig 6: View Of Rivets
    GM1956481Courtesy of GENERAL MOTORS CORP.
    NOTE: Be very careful when removing the rivets so the transfer case does not get damaged.
  9. Using a 5/32 drill bit and a suitable rivet gun, remove the rivets from the heat shield.
  10. Remove the heat shield.
    11. Fig 7: Removing The Rear Output Shaft Seal
    GM1549474Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Transfer Case Seal Removal Caution .
  11. Using the J 2619-01:  hammer (1) and the J 45278:  remover (2), remove the rear output shaft seal.
    12. Fig 8: Loosening Front Output Shaft Flange Nut
    GM1549465Courtesy of GENERAL MOTORS CORP.
  12. Install the J 8614-01:  holding tool to the front output shaft flange.
  13. Hold the J 8614-01:  holding tool and loosen the front output shaft flange nut.
    14. Fig 9: Exploded View OF Output Flange And Components
    GM1549466Courtesy of GENERAL MOTORS CORP.
  14. Remove the front output shaft flange nut (1).
  15. Remove the front output shaft flange washer (2).
  16. Remove the front output shaft flange seal (3).
  17. Remove the front output shaft flange (4).
    18. Fig 10: Removing The Front Output Shaft Seal
    GM1549472Courtesy of GENERAL MOTORS CORP.
  18. Using the J 6125-1B:  remover (1) and the J 23129:  remover (2), remove the front output shaft seal.
    19. Fig 11: Identifying Transfer Case Retaining Bolts
    GM1549476Courtesy of GENERAL MOTORS CORP.
  19. Remove the transfer case retaining bolts and washers.

    Mark the location of the brackets.

    20. Fig 12: Identifying J 45358
    GM1565140Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Machined Surface Damage Caution .
  20. Using the J 45358:  spreader between the tabs on the case halves, shear the sealer that is holding the case halves together.
  21. Using pry bars at each side of the case, remove the case from the locating pins.
    22. Fig 13: View Of Rear Case Half & Front Case Half
    GM1549478Courtesy of GENERAL MOTORS CORP.
  22. Remove the rear case half from the front case half. The rear output shaft is removed with the rear case half.
    23. Fig 14: Identifying Shift Fork Shaft Spring
    GM1549480Courtesy of GENERAL MOTORS CORP.
  23. Remove the shift fork shaft spring.
    24. Fig 15: Identifying Shift Fork Shaft Spring
    GM1549481Courtesy of GENERAL MOTORS CORP.
  24. Remove the rear output sun gear.
    25. Fig 16: Removing/Installing Rear Output Shaft Thrust Washer
    GM1549483Courtesy of GENERAL MOTORS CORP.
  25. Remove the rear output shaft thrust washer.
    26. Fig 17: Identifying Planetary Differential Assembly
    GM1549484Courtesy of GENERAL MOTORS CORP.
  26. Remove the planetary differential assembly.
    27. Fig 18: Identifying Front Output Sun Gear
    GM1549485Courtesy of GENERAL MOTORS CORP.
  27. Remove the front output sun gear.
    28. Fig 19: View Of Chain With Drive Sprocket & Driven Sprocket
    GM1549488Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  28. Remove the chain with the drive sprocket and driven sprocket.
    29. Fig 20: View Of Lockup Mode Shift Fork & Lockup Shift Collar Assembly
    GM1549490Courtesy of GENERAL MOTORS CORP.
  29. Remove the lockup shift collar assembly and lockup mode shift fork.
    30. Fig 21: Identifying Lockup Mode Shift Fork
    GM1565141Courtesy of GENERAL MOTORS CORP.
  30. Remove the lockup mode shift fork from the lockup shift collar assembly.
    31. Fig 22: View Of Lockup Shift Collar Assembly
    GM1565142Courtesy of GENERAL MOTORS CORP.
  31. Disassemble the lockup shift collar assembly, if necessary.
    1. Remove the retainer ring from the sleeve.
    2. Remove the hub.
    3. Remove the spring.
    32. Fig 23: Identifying Inner Lockup Hub
    GM1549492Courtesy of GENERAL MOTORS CORP.
  32. Remove the inner lockup hub.
    33. Fig 24: Upper Thrust Washer
    GM1549497Courtesy of GENERAL MOTORS CORP.
  33. Remove the upper thrust washer.
    34. Fig 25: Locating Magnet
    GM1549494Courtesy of GENERAL MOTORS CORP.
  34. Remove the magnet.
    35. Fig 26: Center Bearing Support
    GM1549498Courtesy of GENERAL MOTORS CORP.
  35. Remove the center bearing support.
    36. Fig 27: Identifying Lower Thrust Washer
    GM1549499Courtesy of GENERAL MOTORS CORP.
  36. Remove the lower thrust washer.
    37. Fig 28: Removing Bearing From Support
    GM1549500Courtesy of GENERAL MOTORS CORP.
  37. Using a pair of needle-nose pliers, spread the snap ring in order to remove the bearing from the support, if necessary.
    38. Fig 29: Identifying Oil Pump Assembly With Hose & Screen
    GM1549502Courtesy of GENERAL MOTORS CORP.
  38. Remove the oil pump assembly with the hose and screen.
    39. Fig 30: Oil Pump, Hose & Oil Pump Screen
    GM1565144Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the oil pump hose from the oil pump screen.
  40. Disconnect the oil pump hose from the oil pump.
    41. Fig 31: Identifying Shift Fork Shaft
    GM1549504Courtesy of GENERAL MOTORS CORP.
  41. Remove the shift fork shaft.
    42. Fig 32: Identifying Shift Cam And Shaft Assembly
    GM1549506Courtesy of GENERAL MOTORS CORP.
    CAUTION: In order to prevent component damage, properly remove and install the shift cam and shaft assembly. When removing or installing the shift cam and shaft assembly, keep the shaft straight and do not tilt. Tilting the shift cam and shaft assembly in the transfer case housing will break the tip on the end of the shaft.
  42. Remove the shift cam and shaft assembly.
    1. Rotate the high/low shift fork roller from the shift cam.
    2. Lift straight up on the shift cam and shaft assembly.
    43. Fig 33: Identifying Mainshaft
    GM1549511Courtesy of GENERAL MOTORS CORP.
  43. Remove the mainshaft.
    44. Fig 34: View Of High/Low Range Sleeve With High/Low Range Shift Fork
    GM1549514Courtesy of GENERAL MOTORS CORP.
  44. Remove the high/low range sleeve with the high/low range shift fork.
    45. Fig 35: View Of Range Shift Fork & Range Shift Sleeve
    GM1565145Courtesy of GENERAL MOTORS CORP.
  45. Remove the range shift fork from the range shift sleeve.
    46. Fig 36: Locating Input Shaft Needle Thrust Bearing
    GM1549515Courtesy of GENERAL MOTORS CORP.
  46. Remove the input shaft needle thrust bearing.
    47. Fig 37: View Of High/Low Planetary Carrier
    GM1549516Courtesy of GENERAL MOTORS CORP.
  47. Remove the 4494 (1) or the 4493 (2) high/low planetary carrier.
    48. Fig 38: Mainshaft Front Support Bearing
    GM1549517Courtesy of GENERAL MOTORS CORP.
  48. Inspect the 4494 (1) or the 4493 (2) mainshaft front support bearing (3) for being faulty. Refer to Transfer Case Cleaning and Inspection .
  49. Using a brass drift and a hammer, remove the mainshaft front support bearing (3) from the planetary carrier assembly.
    50. Fig 39: Removing/Installing Front Output Shaft Assembly
    GM1549518Courtesy of GENERAL MOTORS CORP.
  50. Remove the front output shaft assembly.
    51. Fig 40: View Of Input Seal
    GM849322Courtesy of GENERAL MOTORS CORP.
  51. Using a hammer and a suitable punch, remove the input shaft seal.
    52. Fig 41: Removing Input Gear Bearing From Front Case Half
    GM1593936Courtesy of GENERAL MOTORS CORP.
  52. Using a hammer and a brass drift, remove the input gear bearing from the front case half.
    53. Fig 42: Removing Front Output Shaft Bearing
    GM819623Courtesy of GENERAL MOTORS CORP.
  53. Using a brass drift, remove the front output shaft bearing from the front case half.
    54. Fig 43: Identifying Ring Gear Retaining Ring
    GM1565146Courtesy of GENERAL MOTORS CORP.
  54. Remove the ring gear retaining ring.
    55. Fig 44: Identifying Ring Gear At Front Case Half
    GM1565148Courtesy of GENERAL MOTORS CORP.
  55. Remove the ring gear from the front case half.
    56. Fig 45: Locating Front Case Half Vent
    GM1565149Courtesy of GENERAL MOTORS CORP.
  56. If necessary, remove the vent from the front case half.
    57. Fig 46: Rear Output Shaft Bushing
    GM1549519Courtesy of GENERAL MOTORS CORP.
  57. Using the J 45380:  installer, remove the rear output shaft bushing.
    58. Fig 47: Identifying Rear Output Shaft
    GM1565150Courtesy of GENERAL MOTORS CORP.
  58. 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-face hammer, tap on the end of the rear output shaft.
    59. Fig 48: Removing Speed Sensor Tone Wheel
    GM1565151Courtesy of GENERAL MOTORS CORP.
  59. Using a hydraulic press and the J 22912-B:  adapter, remove the speed sensor tone wheel.

    Do not use the speed sensor tone wheel again.

    60. Fig 49: Identifying Rear Output Shaft Bearing Retaining Ring
    GM1565152Courtesy of GENERAL MOTORS CORP.
  60. Remove the rear output shaft bearing retaining ring.
    61. Fig 50: Rear Output Shaft Bearing
    GM1565153Courtesy of GENERAL MOTORS CORP.
  61. Using a hydraulic press, remove the rear output shaft bearing.
    62. Fig 51: Removing Mainshaft Rear Support Bushing From Rear Output Shaft
    GM1565154Courtesy of GENERAL MOTORS CORP.
  62. Inspect the mainshaft rear support bushing, in the rear output shaft, for being faulty. Refer to Transfer Case Cleaning and Inspection .
  63. Using the J 2619-01:  hammer (1) and the J 45548:  remover (2), remove the mainshaft rear support bushing from the rear output shaft.
    64. Fig 52: Removing Front Output Shaft Rear Bearing From Rear Case
    GM1565155Courtesy of GENERAL MOTORS CORP.
  64. Using the J 29369-1:  remover (1) and the J 23907:  adapter (2), remove the front output shaft rear bearing from the rear case.
    65. Fig 53: Locating Shift Shaft Seal
    GM1565156Courtesy of GENERAL MOTORS CORP.
  65. Remove the D-Ring seal (1).
  66. Remove the shift shaft seal (2) by prying it out of the case.
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