GM 24246930
Transfer Case

Several tools needed to disassemble the Transfer Case include slide hammer (J 2619-01) and holding fixture (J 3289-20) and split plate bearing puller (J 22912-01) and slide hammer with bearing adapter (J 23907) and bushing and bearing remover - 3-4 inch (J 26941) and case spreader (J 45358) and mainshaft support bushing/bearing remover (J 45548). For Transfer Case disassembly you will require slide hammer (J 2619-01), holding fixture (J 3289-20), split plate bearing puller (J 22912-01), slide hammer with bearing adapter (J 23907) as well as bushing and bearing remover - 3-4 inch (J 26941) and case spreader (J 45358) and mainshaft support bushing/bearing remover (J 45548). Attach the assembly fixture (J 45759) to the Transfer Case through adapter studs for mounted case disassembly operations. Weld the assembly fixture (J 45759) to a holding fixture (J 3289-20) set up on a stable workbench before securing the stack with a pivot pin. The process to drain Transfer Case fluid requires removal of both drain and fill plugs. The procedure requires front output shaft seal removal followed by encoder motor assembly extraction and Vehicle Speed Sensor (VSS) removal and finally rear output shaft seal removal. Use the case spreader to shear the sealer between the case halves before removing the Transfer Case retaining bolts together with washers while noting down the brackets' original positions. Apply the case spreader (J 45358) to break the sealer binding between case halves before separating the front from the rear halves of the case. Remove sequentially the shift fork shaft spring together with the rear sun gear planetary Differential assembly and the chain containing drive and driven sprockets. You must mark how the chain and sprockets fit together to keep their wear patterns when reusing them. Attack the remaining components starting with the lockup shift assembly and progressing through the Oil Pump assembly before finally removing the shift detent lever assembly but maintain straight alignment of the shift detent lever shaft assembly throughout the process. To finish the task remove the mainshaft rear support bushing with slide hammer (J 2619-01) and mainshaft support bushing/bearing remover (J 45548) and use the bushing and bearing remover (J 26941) together with slide hammer with bearing adapter (J 23907) to eliminate the rear bearing for the front output shaft.

In the process of putting the Transfer Case together first install the Transfer Case mounting studs and tighten them further to 31 nm (23 ft. Lbs.). Mount the assembly fixture (J 45759) to the front Transfer Case with the aid of the adapter studs, making possible all the assembly procedures while mounted to the fixture. Mount the secure assembly fixture (J 45759) to the holding fixture (J 3289-20) by using the pivot pin. If the vent was removed, treat the threads with gm p/n 12346004 (Cdn. P/N 10953480) pipe sealant and install the vent, with the vent being screwed to 6 nm (53 in.lbs). All bearings and bearing journals need to be lubricated with Transfer Case fluid on tour of installation. Mount the input shaft bearing in the front case half using the hammer and brass drift onto the outer bearing race only making sure that it is square to the bore. Repeat the same process on front bearing of front output shaft. If necessary, mount the cup plug at the front output shaft with the appropriate driver, at a distance of 1 mm (0.039 inch) from the shaft's end. Go ahead and install the front output shaft assembly, input shaft, and align the drive chain, along with the sprockets, with the blue-link on the chain directed upwards. Install the front sun gear ensuring that the planetary Differential gears in it are in time otherwise it causes binding. Before installing the planetary Differential assembly align the marks on the pinion gears with reference area of the planetary housing without allowing the rotations of the pinion gears during installation. Lubricate the sun gear thrust washer with transjel lubricant (J 36850) prior to installing with rear sun gear facing the shoulder end up. Install the rear output shaft temporarily to the planetary Differential and rear sun gear then rotate to see whether it aligns. Take off rear output shaft without disturbing rear sun gear, then install front output shaft rear bearing into rear case half again using hammer and brass drift only on the outer bearing race. Mount the rear output shaft bearing using the hydraulic press and the split plate bearing puller (J 22912-01) with retaining ring groove oriented to the input end. Install a new retaining ring for the rear output shaft bearing and a new speed reluctor wheel via hydraulic press. The help of universal driver handle - non-threaded (j 42176) and mainshaft support bushing and bearing installer (J 45757) should be used to install the input shaft rear support bushing in the rear output shaft and then put the rear output shaft in back case half. Make sure that both sealing surfaces on the front and rear case halves are clean and free of contaminants, and insert the locating pins if required. Make sure that you apply a 3.175 mm (1/8 inch) bead of rtv sealant gm p/n 12345739 (Canadian P/N 10953541) to the mating surfaces of both front case half before you lower the rear case half of it into place aligning the teeths with the planetary carrier accordingly. Make sure the nylon coating on the case bolts is not damaged to have to replace, and hand start the self-tapping case bolts to tighten them to 21 nm (15 ft. Lbs.). Replace the Vehicle Speed Sensor with a new o-ring seal, tighten the pair to 17 nm (13 ft. Lbs.). With the rear output shaft seal installer (J 45756), install the rear output shaft seal, and apply pipe sealant gm p/n 12346004 (Canadian P/N 10953480) to both threads of the drain and fill plugs before installing and fastening to 25 nm (18 ft. Lbs.). Finally, install the front output shaft seal with the help of the front output shaft seal installer (J 43484) and universal driver (J 8092), and take the Transfer Case out of the assembly fixture (J 45759).