OEM Chevrolet Express 3500 Transfer Case

Chevrolet Express 3500 Transfer Case Parts Questions & Experts Answers

• Transfer Case
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  Q: What tools are necessary to disassemble the transfer case on Chevrolet Express 3500?

  A: 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.