For 1990-2009 cars

#### Tools Required

• | J 46003 Output Shaft Bearing Locknut Wrench

• | J 46001 Differential Drive Pinion Holding Tool

### Disassembly

1. Remove the No.1 plug from the transfer case assembly.
2. Remove the No.2 plug from the transfer case assembly.
3. Place a drain pan under the transfer case.
4. Remove the drain plug from the transfer case assembly.
5. Remove the breather plug from the transfer case assembly.
6. Remove the transfer case cover bolts.
7. Using a brass drift and a hammer, remove the transfer case cover from the case.
8. Remove the 3 transfer case mount bolts.
9. Remove the mount from the extension housing.
10. Remove the 4 alignment pins from the transfer case.
11. Using a soft faced hammer, remove the extension housing dust deflector.
12. Remove the oil seal from the extension housing.
13. Remove the 4 extension housing retaining bolts.
14. Remove the extension housing from the transfer case.
15. 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).

16. 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).

17. Coat the teeth of the ring gear with Gear Marking Compound GM P/N 1052351 (Canadian P/N 10953497).
18. Rotate the ring gear.
19. Inspect the ring gear contact pattern.
20. Remove the left transfer case oil seal.
21. Remove the right transfer case oil seal.
22. Remove the bearing cap bolts and bearing cap from the ring gear assembly.
23. Remove the output shaft spacer from the ring gear mounting case.
24. Remove the ring gear mounting case washer.
25. Remove the ring gear mounting case from the transfer case.
26. Using a punch and a hammer, unstake the drive pinion nut.
27. Using J 46003 and J 46001 remove the drive pinion retaining nut.
28. Using a press, remove the drive pinion, spacer and washer from the transfer case.
29. Using a press, remove the drive pinion bearing from the drive pinion.
30. Using a brass bar and a hammer, remove the drive pinion bearing race from the transfer case.
31. Using a press, remove the left and right ring gear mounting case bearings.
32. Using a brass bar and hammer, remove the left outer race from the transfer case.
33. Using a brass bar and hammer, remove the right outer race from the transfer case.
34. Using a dial indicator, check the runout of the ring gear.

Runout
Runout should not exceed 0.06 mm (0.0024 in).

35. Place alignment marks (1) on the ring gear and the mounting case.
36. Remove the 10 ring gear bolts.
37. Using a soft faced hammer, tap on the ring gear to separate it from the ring gear mounting case.
38. Using a dial indicator, check the runout of the ring gear mounting case.

Runout
Runout should not exceed 0.14 mm (0.0055 in).

39. Using a brass bar and hammer, remove the drive pinion bearing race from the transfer case.