Section 4

Driveline/Axle

P ro p eller S h a ft.........................................................4-5 Special Tools and Equipm ent......................... 4-46

S pecifications......... ....... ................. ..................... 4-5 F ront D rive A xle ............. .......... .............. ...... ..... 4-47
Fastener Tightening Specifications ......... .........4-5 Specifications ............. .................................. ......4-47
Propeller Shaft Runout Specifications .............. 4-5 Fastener Tightening Specifications ................ 4-47
GM SPO Group Num bers....... ............ ..............4-5 Lubrication Specifications ....................... .........4-47
Diagnostic Information and Procedures......... 4-6 GM SPO Group Numbers..............................4-47
Leak at Front Slip Y o k e .....................................4-6 Diagnostic Information and Procedures .......4-48
Roughness or Vibration (Normal) ..................... 4-6 Noise Diagnosis (Causes of Noise) ...............4-48
Roughness or Vibration Noise Diagnosis (Determining
(Above 56 km/h 35 M P H )..............................4-6 Type of Noise) .............................................. 4-48
Ping, Snap, or Click Noise .............. ................. 4-7 Front Drive Axle Diagnosis
Knock or Clunk N oise........................ ...... ........4-7 (Clicking Noise in Turns) ............................ 4-49
Scraping Noise ....................................................4-7 Front Drive Axle Diagnosis
(Clunk Accelerating from Coast) ................ 4-49
Squeak Noise ................ ................ .................... 4-7
Front Drive Axle Diagnosis
Shudder on Acceleration at Low Speed ......... 4-7
(Shudder or Vibration) ......................... ....... 4-49
Repair Instructions ............. .......... ......................4-8
Front Drive Axle Diagnosis
Propeller Shaft Replacement (Vibration at Highway Speeds)....................4-50
(Front Axle - All Except NP8) ................. .....4-8 Front Drive Axle Diagnosis
Propeller Shaft Replacement (Front Drive Axle Leaks)..............................4-50
(Front Axle - N P 8 )...........................................4-9 Four-Wheel-Drive Diagnosis
Propeller Shaft Replacement (4WD Will Not Engage) ............................... 4-50
(System Balanced Assembly)......................4-12 Four-Wheel-Drive Diagnosis
Propeller Shaft Replacement - (4WD Does Not Disengage) ....................... 4-50
One-Piece ...................................................... 4-13 Four-Wheel-Drive Diagnosis
Propeller Shaft Replacement - (Indicator Light Not Off) ............................... 4-50
Two-Piece ................................. .................... 4-15 Four-Wheel-Drive Diagnosis
Propeller Shaft Replacement - (Indicator Light Not On) ............................... 4-50
Three-Piece................ ................................... 4-18 Electric Motor Actuator C heck........................ 4-51
Center Bearing Replacement ..........................4-21 Repair In structions............................................ 4-51
Universal Joints Replacement Lubricant Change........................................ ..... 4-51
(Nylon Injected Ring Type) ......................... 4-22 Shield Replacement .......................... .............. 4-52
Universal Joints Replacement Indicator Switch Replacement .........................4-53
(External Snap Ring Type) .........................4-24 Electric Motor Actuator Replacement.............4-54
Description and O peration...............................4-27 Vent Hose Replacement .......... .......................4-54
Propeller Shaft Description ............................ ..4-27 Shift Fork Replacement....................................4-55
Universal Joint Description ..............................4-27 Shift Mechanism Inspection........................ ....4-56
Center Bearing Description ......... ................... 4-28 Output Shaft, Bearing, and Tube
Special Tools and Equipm ent......................... 4-28 Replacement (Right Side) .................... .......4-56
Axle Shaft and Seal Replacement.................4-57
W heel D rive S h a f t s ................ ................. ..........4-29 Differential Pilot Bearing Replacement.......... 4-58
Specifications .............................................. ..4-29 Pinion, Flange, and Dust Deflector
Fastener Tightening Specifications ................4-29 Replacement .......................... .............. ........4-59
Visual identification................ ............ .............. 4-30 Differential Carrier Bushing Replacement .....4-61
Disassembled Views .......... ................. ...........4-30 Differential Carrier Assembly Replacement ...4-62
Repair Instru ction s........... ................................4-31 Halfshaft Assembly Replacement ...................4-64
Deflector Ring Replacement........ ........ ..........4-31 Differential Carrier Overhaul ........ ...................4-69
Inner Joint and Seal Replacement ...............4-32 Differential Assembly Installation ................... 4-78
Outer Joint and Seal Replacement................4-37 Cleaning Carrier Components ........................ 4-79
Wheel Drive Shafts Boot Cover Ring and Pinion Gear Inspection....................4-79
Replacement ............ .............. ...................... 4-42 Bearings Inspection...........................................4-80
 Thrust Washers, Shims, and Adjuster Axle Replacement (11 Inch Ring Gear) ......4-146
Sleeves ...........................................................4-80 Axle Replacement (Rear Axle Assembly) ...4-147
Pinion Bearing Cup Installation ...................... 4-80 Axle Replacement
Pinion Depth Adjustment............................... ..4-81 (Assembly Replacement 11 Inch).............4-149
Pinion Installation.............................................. 4-83 Hub and Drum Assembly Replacement......4-150
Differential Case Assembly Assemble .......... 4-84 Hub and Rotor Assembly Replacement ......4-152
Carrier Case Assembly..................................4-85 Bearing Cup Replacement
Backlash Inspection and Adjustment .............4-88 (10 1/2 Inch Ring Gear) ............................4-153
Gear Tooth Contact Pattern Check ............... 4-90 Bearing Cup Replacement
Axle Tube Assembly.........................................4-91 (11 Inch Ring Gear) ................................... 4-155
Differential Carrier Final Assembly .................4-94 Wheel Bearing Adjustment
Description and O peration.......... .................... 4-95 (10 1/2 Inch Ring Gear) ......................... ..4-157
Front Drive Axle Description ........................... 4-95 Wheel Bearing Adjustment
(11 Inch Ring Gear A xle)................. .........4-159
Special Tools and E quipm ent......................... 4-96
Description and Operation .............................4-160
R ear D rive A xle .................................................. 4-100 Rear Axle Description .................................... 4-160
Specifications ................................ ...................4-100 Special Too l s and Equipm ent.......................4-161
Fastener Tightening Specifications
(8 1/2 and 8 5/8) ....................................... 4-100 R ear D rive A xle - L o cking/Lim ited
Fastener Tightening Specifications S lip R ear A xle ............. .............. .....4-164
(9 1/2 In Ring G e a r)...................................4-100 Specifications ..................... ............................. 4-164
Fastener Tightening Specifications Fastener Tightening Specifications ............. 4-164
(10 1/2 In Ring Gear) ................................ 4-100 Thrust Block Sizes (Locking)................... ....4-164
Fastener Tightening Specifications Reaction Block, 10 1/2 Inch Axle ................ 4-164
(11 Inch Ring Gear) ............................ ...... 4-100 Lubrication Specifications ........................ ..... 4-164
Spacer and Shim Specifications ...................4-100 Repair In stru ctio n s........................ ..................4-165
Pinion Bearing and Differential Bearing Locking Differential Disassemble
Preload............................................. ............ 4-101 (10 1/2 Case) ............................................ ..4-165
Lubrication Specifications ..............................4-101 Locking Differential Disassemble
GM SPO Group Numbers ............... ............. 4-102 (8 1/2 and 9 1/2 C a s e )............................. 4-171
Component L o cato r................................ .........4-103 Locking Differential Cam Unit
Rear Axle Disassembled Views .................... 4-103 Disassemble (10 1/2 Assembly) ............... 4-172
Diagnostic Information and Procedures .....4-106 Locking Differential Cam Unit
Determining Type of N oise........................... 4-106 Disassemble (7 5/8 and 8.6 Assembly) ...4-173
Rear Axle Wheel Bearing Wear ................... 4-108 Locking Differential Cleaning and
Repair Instructions...........................................4-112 Inspection ..................................................... 4-173
Oil Seal and/or Bearing Replacement......... 4-112 Locking Differential Cam Unit Assemble.....4-174
Pinion Oil Seal Replacement Locking Differential Adjustment.....................4-174
(Semi-Floating Axle) ....................... ...........4-117 Locking Differential Assemble....................... 4-175
Pinion Oil Seal Replacement Special Too ls and E quipm ent.......................4-176
(10 1/2 Inch Ring Gear) ............................ 4-120
Pinion Oil Seal Replacement T ran sfer C ase .....................................................4-177
(11 Inch Ring Gear) .................................. 4-123 Specifications .......... .........................................4-177
Vent Hose Replacement ........................ ......4-125 Fastener Tightening Specifications
Inspection Before Disassembly.................... 4-127 (Manual Shift Transfer Case) .................. .4-177
Drive Axle Disassemble .............. .................. 4-128 Approximate Fluid Capacities ....................... 4-177
Axle Housing Inspection................................ 4-133 Schematic and Routing Diagrams ......... ..... 4-178
Differential Inspection ...................... ............ ..4-133 Transfer Case Control Schematic
Pinion and Ring Gear Inspection................. 4-133 References .... ...................... ...................... 4-178
Bearings Inspection............................... ....... .4-133 Transfer Case Control Schematic Icons .....4-178
Shims Inspection .............................. .............. 4-133 Transfer Case Control Schematics
Pinion Depth Adjustment.......... ....................4-134 (Selectable 4 W D )............... .........................4-179
Differential Case Assembly....................... ....4-136 Component L o cator........... ................... .........4-184
Determining Total Shim Pack Size ..............4-137 Transfer Case Control Components ............4-184
Pinion Installation........ ..................... ............ .4-138 Transfer Case Control Component
Differential to Axle Housing Assemble ........4-140 Views (Selectable 4WD) ......... ..................4-187
Backlash Adjustment..................................... .4-142 Transfer Case Control Component
Gear Tooth Contact Pattern Check ............4-143 Views (Automatic 4WD) ............................. 4-197
Drive Axle Final Assembly ............................4-145 Transfer Case Control Connector End
Axle Replacement (10 1/2 In Ring Gear) ...4-146 Views (Selectable 4WD) ................ ........... 4-199
 Transfer Case Control Connector End Views Description and O p e ra tio n ..... .....................4-232
(Automatic 4WD) ...................... ............ .....4-201 Transfer Case Description
Diagnostic Information and Procedures .....4-204 (Selectable 4 W D )..................................... 4-232
Troubleshooting Hints (Selectable 4 W D ).....4-204 Transfer Case System Description
Troubleshooting Hints (Automatic 4WD) .....4-204 (Selectable 4 W D )....................... .......... ......4-234
System Diagnosis (Automatic 4WD) ...........4-204 Transfer Case System Description
Diagnostic Trouble Codes ............ ....... .........4-206 (Automatic 4WD) ... ............................4-234
Obtaining Diagnostic Trouble Codes............4-206 Mode Shifts ......... ............................ ..............4-235
Clearing Memory (Selectable 4 W D )............. 4-207 Range Shifts ........... .........4-235
Transfer Case Functional Test ...................4-207 Transfer Case Control Module
Functional Test Failed .............. ............ ........4-208 Description ............. ............................... ..... 4-235
All Shift Select Buttons Do Not Light..........4-209 RAM/ROM Check ............. .............. ............4-236
O ne or Two Shift Select Buttons Do Data Memory Retention C heck....................4-236
Not Light ...................... ............ ........... ....... 4-210 Encoder Signal Check......... ..........................4-236
All Shift Select Buttons Remain L it.............. 4-211 Encoder Switch Monitor Check......... .....4-236
More Than One Shift Select Button Motor and Relay Voltage Checks ............. ...4-236
Remains L it ............................... ................. 4-212 Motor/Encoder Circuit Operation ............. ......4-236
No Shift Select Buttons Remain L it ............ 4-212 Special Tools and Equipment ................. .....4-236
Reduced or No Mode and Range Shift T ra n s fe r C ase - NVG 246-N P 8
O peration ............................................... . .4-213 (T w o Speed A u to m a tic )......... ..... 4-237
Perform a Diagnostic On the TCCM ...........4-213
Specifications ................................. ...... .......... 4-237
Four-Wheel-Drive Does Not Disengage
Fastener Tightening Specifications
(Selectable 4 W D )........................................ 4-213
(Auto Transfer Case) ..................................4-237
Four-Wheel-Drive Does Not Engage
Approximate Fluid Capacities ....................... 4-237
(Selectable 4 W D )........................................ 4-213
Scan Tool Data L is t....................................... 4-237
Four-Wheel-Drive Indicator Does Not
Scan Tool Data Definitions............................4-239
Light (Selectable 4 W D )..............................4-214
Schematic and Routing Diagrams ............... 4-240
Four-Wheel-Drive Indicator Does Not
Turn Off (Selectable 4 W D )........................ 4-214 Transfer Case Control Schematic
Transfer Case Electronic Shift System References ...................................................4-240
Diagnosis (Selectable 4 W D )...................... 4-214 Transfer Case Control Schematic Icons .....4-240
Transfer Case Diagnosis Transfer Case Control Schematics
(Selectable 4 W D )........................................ 4-214 (Automatic 4WD) ........................................ 4-241
Repair Instru ctio ns...........................................4-215 Component L o cato r..........................................4-243
Oil Replacement .............................................4-215 Transfer Case Control Components ............4-243
Shield Replacement....................................... 4-215 Transfer Case Control Component Views ...4-246
Shift Cable Replacement............................... 4-216 Transfer Case Control Connector End
Views ............................................................ 4-253
Shift Lever Replacement - On Vehicle .......4-217
Diagnostic Information and P rocedures.....4-257
Transfer Case Output Shaft Seal
Intermittents and Poor Connections.............4-257
Replacement (New Venture) .....................4-219
Transfer Case General Diagnosis................ 4-257
Transfer Case Output Shaft Seal
Transfer Case Diagnostic System Check ....4-257
Replacement (Borg-Wamer)...................... 4-220
Diagnostic Trouble Codes ............................. 4-260
Rear Extension Housing Replacement........ 4-221
DTC B0768 Service Indicator
Transfer Case Replacement
Circuit High ................................................. 4-261
(Selectable Four Wheel Drive) ................. 4-223
DTC B2725 ATC Mode Switch Circuit
Transfer Case Replacement Malfunction ................................................ .4-263
(Manual Four Wheel D rive)....................... 4-225
DTC C0300 Rear Speed Sensor
Adapter Replacement.....................................4-227 Malfunction ...................................................4-266
Motor/Encoder Replacement DTC C0305 Front Speed Sensor
(Selectable 4 W D )........................................ 4-228 Malfunction.................................................. 4-269
Transfer Case Driver Control Switch DTC C0308 Motor A/B Circuit L o w .............. 4-272
Replacement (Selectable 4 W D )................ 4-229 DTC C0309 Motor A/B Circuit High .............4-274
Transfer Case Control Module DTC C0310 Motor A/B Circuit O p e n ............4-276
Replacement (Auto Transfer Case) ......... 4-230 DTCC0315 Motor Ground Circuit Open .....4-278
Speed Sensor Replacement DTC C0323 T-Case Lock Circuit Lo w ......... 4-280
(Front Speed Sensor Replacement) ........ 4-231 DTC C0324 T-Case Lock Circuit High ........ 4-282
Speed Sensor Replacement DTC C0327 Encoder Circuit Malfunction.....4-284
(Rear Speed Sensor Replacement)......... 4-231 DTC C0357 Park Switch Circuit High ......... 4-287
Transfer Case Electrical Connector DTC C0362 4LO Discrete O utput
Replacement (Selectable 4 W D )................ 4-232 Circuit High ..................................................4-289
DTC C0367 Front Axle Control Repair Instructions................................ ..........4-320
Circuit High ............................... .................. 4-291 Oil Replacement .............................................4-320
DTC C0374 General System Malfunction ....4-293 Shield Replacement .......................................4-320
DTC C0376 Front/Rear Shaft Speed Transfer Case Output Shaft Seal
Mismatch...................................................... 4-294 Replacement (New Venture) .....................4-321
DTC C0550 ECU Malfunction ....................... 4-296 Transfer Case Replacement
DTC C0611 VIN Information E rro r............... 4-297 (Auto Four Wheel Drive ) ............ ....... .....4-322
DTC C0895 Device Voltage Malfunction .....4-298 Motor/Encoder Replacement
Front Axle Will Not Engage.......................... 4-301 (Automatic 4WD) ....................................... .4-325
Front Axle Will Not Disengage ................. ...4-304 Transfer Case Driver Control Switch
Range/Mode Switch Inoperative ................. .4-307 Replacement (Automatic 4WD) ............ ....4-326
Transfer Case Control Module
No Correction for Slip in AWD Mode ......... 4-309
Replacement (Automatic 4WD) .................4-327
Switch Indicator Lamps Flash
Speed Sensor Replacement
Continuously................................................ 4-310
(Front Speed Sensor Replacement) ........ 4-327
Switch Indicator Lamps Remain ON -
Two or M ore................................................ 4-312 Speed Sensor Replacement
(Rear Speed Sensor Replacement)......... 4-328
Switch Indicator Lamps Do Not Light -
Description and Operation .............................4-329
One or M ore................................................ 4-314
Transfer Case Circuit Description .................4-329
Service Indicator Stays ON When
Key is ON .................................................... 4-316 Special Tools and Equipm ent......... ............. 4-329
Service Indicator Does Not Light................. 4-318
Propeller Shaft
Specifications
Fastener Tightening Specifications
Specification
Application Metric English
Center Bearing Mounting Bolt 35 N*m 26 Ib ft
Front Axle Yoke Retainer Bolt 20 N-m 151b ft
Rear Axle Yoke Retainer Bolt C/K 1 ,2,3 Except C3500HD 20 N-m 151b ft
Rear Axle Yoke Retainer Bolt C3500HD 37 N-m 271b ft
Transmission Parking Brake Drum Flange Bolt 37 N-m 271b ft
Transfer Case Yoke Retainer Bolt 20 N-m 15 Ib ft
Transmission Yoke Retainer Bolt 20 N-m 15 Ib ft

Propeller Shaft Runout Specifications

Propeller Front Center
Shaft Check Check Rear Check
One Piece 0.025 in 0.050 in 0.025 in
Two Piece Driveshaft:
Front Piece 0.025 in 0.005 in* — -
- Rear Piece — 0.030 in** 0.030 in
This measurement must be taken on the ground surface
near the spline with the rear propeller shaft removed.
'"This measurement must be taken with the rear propeller
shaft mounted on the front shaft which is within
specifications.

GM SPO Group Numbers

/.plication GM SPO Group Number
Center Bearing, Bearing, Cushion and Retainer 5.600
Propeller Shat- 5 544
Propeller Sha-t Bearing Shields, Slinger and Washer 5.601
Propeller Shaft Bolt, Bracket, Hanger, Nut, Reinforcement, Support and Washer 5.598
Propeller Shaft Internal Cam and Shoe Brake Bolt, Drum, Nut, Plate, Shield, Shoe Kit,
5.605
Spring and Washer
Propeller Shaft Pinion Deflector, Flange and Yoke 5 545
Propeller Shaft Universal Joint, Joint Kit 5 548
Propeller Shaft Universal Joint Trunnion Ring and Seal 5 560
Universal Joint and Power Divider Deflector and Yoke 5 555
Universal Joint Sleeve Yoke Bushing, Cap, Nut and Washer 5.556
Universal Joint Trunnion and Yoke Bolt, Boot Kit, Clamp, Nut and Retainer 5 586 ;
Universal Joint Yoke Trunnion Bearing 5 566
 Leak at Front Slip Yoke
Checks Action
DEFINITION: An occasional drop of lubricant leaking from the splined yoke is normal and requires no attention.
The slip yoke barrel is burred, nicked, • Replace the seal.
corroded, or worn.
• Smooth minor burrs by careful use of crocus cloth or fine stone honing.
• Replace a badly burred yoke.
A defective transmission rear oil seal. Replace the transmission rear oil seal and replenish the transmission oil.

Roughness or Vibration (Normal)

Checks Action
DEFINITION: The roughness or vibration occurs while driving the vehicle at various speeds.
A bent or dented propeller shaft. Replace the propeller shaft. Refer to Propeller Shaft Replacement - One-Piece or
Propeller Shaft Replacement - Two-Piece.
Undercoating is on the Clean the propeller shaft.
propeller shaft.
The tires are unbalanced at Balance or replace the tires.
48-80 km/h (30-50 mph).
The universal joints are tight. On snap ring retainer U-joints, tap the yokes with a hammer in order to free up the
U-joints. If you are unable to free up the U-joints, or if the joint feels rough, replace
the joint.
The universal joints are worn. Replace the worn universal joints.
The companion flange is bent or has Refer to Pinion Installation in Vibration Diagnosis.
excessive runout.
Burrs or gouges are on the • Inspect the snap ring locating surfaces on the flange yoke.
companion flange.
• Deburr or replace the companion flange.
The propeller shaft, parking brake • Check for a missing balance weight on all three components.
drum, or the companion flange is
unbalanced. • rotate the propeller shaft in the companion flange 180 degrees.

Incorrect rear joint angle usually as • Inspect and correct the trim height at curb weight.
result of the angle being too large.
• Inspect and correct the joint angle. Refer to Driveline Vibration Analysis in
Vibration Diagnosis.
Excessive looseness at the slip Replace the necessary parts.
spline.
Distorted or damaged yokes or Install new yokes or flanges.
flanges.
The yokes are out of phase on Re-index the propeller shaft.
two-piece propeller shaft system.
The driveline vibration is at Inspect the propeller shaft for runout and for missing balance weights. Refer to
80 km/h (50 mph). Driveline Vibration Analysis in Vibration Diagnosis.
The propeller shaft and axle flange Align the paint marks as close as possible.
paint marks are misaligned by more
than 90 degrees.

Roughness or Vibration (Above 56 km/h 35 MPH)

Checks | Action
DEFINITION: One hears or feels a roughness when driving the vehicle above 56 km/h (35 mph).
The tires are unbalanced or worn. Balance or replace the tires.
 Ping, Snap, or Click Noise
Checks Action
DEFINITION: A ping, snap or click is usually heard on initial load after the transmission is in gear, either forward or reverse.
The rear springs or upper and lower Tighten the bolts to specified torque refer to Fastener Tightening Specifications.
control arms have loose
bushing bolts.
A loose fixed yoke or companion Tighten the bolts and pinion nut to specified torque refer to Fastener Tightening
flange. Specifications.
Worn or damaged universal joints. Replace the universal joints. Refer to Universal Joints Replacement (Nylon Injected
Ring Type) or Universal Joints Replacement (External Snap Ring Type).

Knock or Clunk Noise

Checks Action
DEFINITION: Knocking or clunking noise occurs when operating the vehicle in high gear or coasting in neutral at
16 km/h ( 1 0 mph).
A worn or damaged universal joint. Replace the worn or damaged universal joint. Refer to Universal Joints Replacement
(Nylon Injected Ring Type) and Universal Joints Replacement (External
Snap Ring Type).
The side gear hub counterbore in the Replace the differential case and/or the side gears.
differential is worn oversize.

Scraping Noise
Checks Action
DEFINITION: A scraping noise occurs when driving the vehicle at various speeds.
The pinion flange, or center bearing Correct the interference.
is rubbing.

Squeak Noise
Checks Action
DEFINITION: When driving the vehicle at various speeds a squeaking sound occurs.
Lack of lubricant. Replace the universal joints as required. Refer to Universal Joints Replacement
(Nylon Injected Ring Type) and Universal Joints Replacement (External
Snap Ring Type).

Shudder on Acceleration at Low Speed

Checks Action
DEFINITION: When accelerating the vehicle at low speed a shudder occurs.
Bolts are loose or missing at the Replace or tighten the bolts to specified torque. Refer to Fastener Tightening
flanges. Specifications.
The joint angle is excessive or Shim under the transmission support mount in order to change the joint angle. Use
incorrectly set. the standard shim P/N 1254001, or shim the axle pinion down.
The universal joint is worn. Replace the universal joint. Refer to Universal Joints Replacement (Nylon Injected
Ring Type) or Universal Joints Replacement (External Snap Ring Type).
Repair Instructions
Propeller Shaft Replacement 9. Clean all parts with an approved solvent.
(Front Axle - All Except NP8) 10. Inspect the splines for damage, wear, burrs, and
twisting.
Removal Procedure 11 . Inspect the universal joint bearings for wear.
1. Raise the vehicle on a hoist. 12. Inspect the propeller shaft for any evidence of
2. Remove the front differential carrier shield, if damage.
used. Refer to Shield Replacement.
Installation Procedure
Important: Observe and accurately reference mark all
1. Extend the propeller shaft to its full length, then
driveline components relative to the propeller shaft
compress it about half its stroke.
and axles before disassembly. These components
include the propeller shafts, drive axles, pinion flanges, 2. Install the propeller shaft to the front axle by lining
output shafts, etc. All components must be up the reference marks made previously.
reassembled in the exact relationship to each other as N o tic e : Refer to Fastener Notice in Cautions and
they were when removed. In addition, published Notices.
specifications and torque values, as well as any
3. Install the retainers and bolts.
measurements made prior to disassembly must be
followed. Tighten
3. Reference mark the relationship of the propeller Tighten the retainer bolts to 20 N-m (15 Ib ft).
shaft to the front axle and the transfer case 4. Install the propeller shaft to the transfer case.
flange. 4.1. Line up the reference marks made
4. Remove the bolts and the retainers from the previously.
front axle. 4.2. Adjust the propeller shaft length.
5. Remove the bolts and retainers from the 4.3. Support the propeller shaft.
transfer case.
5. Install the retainers and bolts.
N o tic e : When removing the propeller shaft, do not
Tighten
attempt to remove the shaft by pounding on the yoke
ears or using a tool between the yoke and the Tighten the retainer bolts to 20 N-m (15 Ib ft).
universal joint. If the propeller shaft is removed by 6 . Install the front differential carrier shield, if
using such means, the injection joints may fracture and equipped. Refer to Shield Replacement.
lead to premature failure of the joint.
Important: If the slip spline is dry or corroded, it may
6 . Remove the propeller shaft. be necessary to disconnect the propeller shaft
7. Compress the propeller shaft forward enough to from the vehicle. Wipe the spline clean before
disengage, then move the propeller shaft installation.
rearward. 7. Apply chassis lubricant at the slip spline grease
8 . Avoid dropping the bearing cap assemblies from fitting until the grease begins to leave through the
the yoke ends. vent hole.
Propeller Shaft Replacement
(Front Axle - NP8)
Removal Procedure
Tools Required
J 43 2 1 8 Clamp Pliers
1. Position the transmission range select lever to
Neutral (N) and release the park brake.
2. Raise and support the vehicle.
3. Remove the transfer case shield, if equipped.
Refer to Shield R ep lacem en t
4. Remove the nut securing the transmission control
lever to the manual control shaft.
5. Remove the transmission control lever from the
manual control shaft.
6 . Check the universal joints for looseness.
7. Remove the boot clamp at the transfer case end
by prying up the exposed end of the clamp with a 319774
flat bladed tool.
Important: Observe and accurately reference mark all
driveline components relative to the propeller shaft
and axles before disassembly. These components
include the propeller shafts, drive axles, pinion flanges,
output shafts, etc. All components must be
reassembled in the exact relationship to each other as
they were when removed. In addition, published
specifications and torque values, as well as any
measurements made prior to disassembly must be
followed.
8 . Reference mark the relationship of the propeller
shaft to the front axle.
9. Remove the bolts and the retainers from the
front axle.
 10. Rotate the front axle yoke (1) until the retainer
ends are at the 2 : 0 0 and 8 : 0 0 positions.
11. Slide the propeller shaft rearward enough to
disengage.
N o tic e : When removing the propeller shaft, do not
attempt to remove the shaft by pounding on the yoke
ears or using a tool between the yoke and the
universal joint. If the propeller shaft is removed by
using such means, the injection joints may fracture and
lead to premature failure of the joint.
12. Disengage the propeller shaft by moving it
rearward.

13. Rotate the propeller shaft (1) 90 degrees in

relation to the front axle yoke (2 ).

360936

14. Slide the propeller shaft boot (2) out of the groove
on the OD of the output shaft (1).
15. Remove the propeller shaft from the transfer case
output shaft by sliding it forward.
Important: Avoid dropping the bearing cap assemblies
of the yoke end.
16. Remove the propeller shaft.
17. Inspect the propeller shaft for any evidence of
damage.

360961
Installation Procedure
1. Verify that the splines of the transfer case are
coated with sufficient grease. If not, use special
Teflon grease (GM P/N 12345879).
2 . Place the new clamp in the groove of the propeller
shaft boot.
3. Install the propeller shaft splines into the transfer
case output shaft.
4. install the boot onto the transfer case output shaft
until the boot snaps into the groove on the OD of
the output shaft.
5. Install the propeller shaft to the front axle.
5.1. Line up the reference marks made
previously.
5.2. Install the propeller shaft to the flange.

N o tic e : Refer to Fastener Notice in Cautions and

Notices.

6 . Install the retainers and bolts.

Tighten
Tighten the retainer bolts to 20 N-m (15 Ib ft).
7. Install the transmission control lever to the manual
control shaft with the nut.
Tighten
Tighten the transmission control lever nut to
28 N-m (21 Ib ft).

8 . Crimp the clamp with J 4 3 2 1 8 according to

crimping specifications.
9. Install the transfer case shield, if equipped. Refer
to Shield Replacement.
10. Lower the vehicle.
1 1 . Position the steering column transmission shift
lever to PARK (P).

319738
Propeller Shaft Replacement
(System Balanced Assembly)
Removal Procedure
Important: If one propeller shaft of a system balanced
assembly is replaced, the mating shaft must be
rebalanced with the replaced shaft.
1. Raise the vehicle on a hoist.
Important: Center slip yokes to spline shafts, end
yokes, companion flanges, etc. must not be rotated
from their original position during reassembly.
2. Reference mark all propeller shaft related
components for reassembly including
flanges and yokes.
3. Remove the bolts and retainers.
4. Remove the propeller shaft.
5. Clean the propeller shaft, universal joints, and
attachments with an approved solvent.

Installation Procedure
1. Install the propeller shaft.
2. Install the bolts and retainers.
Tighten
• Tighten the bolts to 20 N-m (15 Ib ft).
• Tighten the bolts 37 N-m (27 Ib ft).
N o tic e : Refer to Fastener Notice in Cautions and
Notices.
Propeller Shaft Replacement - One-Piece
Removal Procedure
Important: Observe and accurately reference mark all
driveline components relative to the propeller shaft
and axles before disassembly. These components
include the propeller shafts, drive axles, pinion flanges,
output shafts, etc. All components must be
reassembled in the exact relationship to each other as
they were when removed. In addition, published
specifications and torque values, as w e ll as any
measurements made prior to disassembly must be
followed.
1 . Reference mark the propeller shaft to pinion
flange connection.
2. Reference mark the slip yoke to the transmission
for proper reassembly.
3. When servicing driveshafts with the pop on seal,
do not remove the seal from the sleeve. Removal
1247
of the seal causes damage to the seal lip
where it contacts the sleeve yoke. If removal of
the seal is necessary, replace the seal with a
new unit.
4. Remove the bolts.
5. Remove the retainers.
N o tic e : When removing the propeller shaft, do not
attempt to remove the shaft by pounding on the yoke
ears or using a tool between the yoke and the
universal joint. If the propeller shaft is removed by
using such means, the injection joints may fracture and
lead to premature failure of the joint.
6 . Remove the yoke and cross assembly, wrapping
the bearing cups with tape in order to prevent the
loss of bearing rollers.
7. Remove the propeller shaft.

404282
 8 . Remove the propeller shaft.
8.1. Slide the propeller shaft forward.
8.2. Lower the propeller shaft.
8.3. Do not allow the universal joint to incline
greatly. The joint may fracture,
8.4. Remove the propeller shaft from the
transmission.

9. Use the following procedure in order to remove

the front propeller shaft:
9.1. Always support the propeller shaft.
9.2. Do not allow the universal joint to bend
deeply as the universal joint could fracture.
9.3. Remove the propeller shaft with a rearward
movement.
10. Clean all parts with an approved solvent.
11. Inspect the outer diameter of the transmission
yoke for burrs. Burring damages the
transmission seal.
12. Inspect the slip yoke splines for wear.
13. Inspect for twisted slip yoke splines or possibly
the wrong universal joint.
14. Inspect the universal joint bearings for wear.
Replace as necessary.

Installation Procedure
1. Install the propeller shaft into the transmission.
2. Lubricate the slip joint spline with chassis grease.
3. Align the reference marks on the pinion flange
and the propeller shaft rear yoke.

404287
 4. Install the yoke and cross assembly onto the I
fixed yoke.

404282

5. Install the retainers.

Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the bolts.
Tighten
Tighten the bolts to 20 N-m (15 Ib ft).

Propeller Shaft Replacement - Two-Piece

Removal Procedure
1. Raise the vehicle on a hoist.
Important: Observe and accurately reference mark all
driveline components relative to the propeller shaft
and axles before disassembly. These components
include the propeller shafts, drive axles, pinion flanges,
output shafts, etc. All components must be
reassembled in the exact relationship to each other as
they were when removed. In addition, published
specifications and torque values, as well as any
measurements made prior to disassembly must be
followed.
2. Reference mark the propeller shaft to pinion
flange connection.
3. Reference mark the slip yoke to the transmission
for proper reassembly.
 4. When servicing propeller shafts with the pop on
seal, do not remove the seal from the sleeve.
Removal of the seal causes damage to the seal
lip where it contacts the sleeve yoke. If removal of
the seal is necessary, replace the seal with a
new part.
5. Remove the retainer bolts.
6. Remove the retainers.
Notice: When removing the propeller shaft, do not
attempt to remove the shaft by pounding on the yoke
ears or using a tool between the yoke and the
universal joint. If the propeller shaft is removed by
using such means, the injection joints may fracture and
lead to premature failure of the joint.
7. Remove the yoke and cross assembly, wrapping
the bearing cups with tape in order to prevent the
loss of bearing rollers.

8. For two-piece Dana propeller shafts, pull the slip

yoke (4) out of the stub shaft (1).
9. For two-piece American Axle and Manufacturing
propeller shafts, unscrew the threaded cap on the
center slip yoke.
10. Remove the propeller shaft.
10.1. Slide the propeller shaft forward.
10.2. Lower the propeller shaft and remove the
propeller shaft.
10.3. Do not allow the universal joint to incline
greatly. The joint may fracture.
11. Remove the center bearing support bolts.
12. Remove the center support bearing nuts and
washers.
13. Remove the center bearing support (3).

157065
14. Remove the front propeller shaft.
14.1. Support the propeller shaft.
14.2. Do not allow the universal joint to bend
deeply as the universal joint could fracture.
14.3. Remove the propeller shaft with a rearward
movement.
15. Clean all parts with an approved solvent.
16. Inspect the outer diameter of the transmission
yoke for burrs. Burring damages the
transmission seal.
17. Inspect the slip yoke splines for wear.
18. Inspect for twisted slip yoke splines or possibly
the wrong universal joint.
19. Inspect the universal joint bearings for wear.
Replace as necessary.

404287

Installation Procedure
1. Install the propeller shaft into the transmission.
2. Ensure that the slip joint splines are lubricated.
3. Bottom the propeller shaft yoke in the
transmission.

4. Install the center bearing support.

5. Align the center bearing support 90 degrees to the
propeller shaft center lines.
Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the center bearing support bolts.
 7. Install the slip yoke (4) by aligning the missing
tooth (5) with the bridged tooth (6) on the splined
shaft (1).
8. Support the propeller shaft.
9. Ensure the slip yoke ears are horizontal.
10. Align the reference marks and install the propeller
shaft to the rear differential yoke.
11. Install the retainers.
12. Install the bolts.
Tighten
Tighten the bolts to 20 N«m (15 Ib ft),
13. Inspect for proper joint fit
14. Lubricate the center slip joint on two-piece shaft.

157065

Propeller Shaft Replacement - Three-Piece

Removal Procedure
1. Raise the vehicle on a hoist
Important: Observe and accurately reference mark all
driveline components relative to the propeller shaft
and axles before disassembly. These components
include the propeller shafts, drive axles, pinion flanges,
output shafts, etc. All components must be
reassembled in the exact relationship to each other as
they were when removed. In addition, published
specifications and torque values, as well as any
measurements made prior to disassembly must be
followed.
2. Reference mark the rear propeller shaft to the
pinion flange connection.
3. Support the rear propeller shaft.
4. Remove the bolts from the pinion flange.
5. Remove the retainers.

Important: Do not pound on the original propeller

shaft yoke ears. The plastic injection joints may
fracture. Never pry or place any tool between a yoke
and a universal joint. Tape the bearing cups onto
the yoke in order to prevent the loss of bearing rollers.
6. Remove the yoke and the universal joint
assembly from the pinion flange.
7. Remove the rear propeller shaft.
• Slide the rear .-propeller shaft forward.
• Lower the rear propeller shaft and withdraw
under the rear axle.
• Do not allow the universal joint assembly to
incline greatly. The joint may fracture.
• Reference mark the intermediate propeller
shaft to front propeller shaft yoke.
• Support the intermediate propeller shaft.
 8. Remove the bolts from the front propeller shaft
yoke at the front center bearing support.
9. Remove the retainers.
10. Remove the nuts from the intermediate shaft
center bearing support.
11. Remove the bolts and washers.
12. Remove the intermediate propeller shaft center
bearing support from the hanger.
Important: Do not pound on the original propeller
shaft yoke ears. The plastic injection joints may
fracture. Never pry or place any tool between a yoke
and a universal joint. Tape the bearing cups onto
the yoke in order to prevent the loss of bearing rollers.
13. Remove the yoke and the universal joint
assembly from the front propeller shaft rear yoke.
14. Remove the intermediate propeller shaft.
• Reference mark the front the propeller shaft to
the yoke or to the parking break drum.
• Support the front propeller shaft.
15. Remove the bolts and the retainers from the yoke.
16. Remove the nuts from the front propeller shaft
center bearing support.
17. Remove the bolts and washers.
Important: Do not pound on the original propeller
shaft yoke ears. The plastic injection joints may
fracture. Never pry or place any tool between a yoke
and a universal joint. Tape the bearing cups onto
the yoke in order to prevent the loss of bearing rollers.
18. Remove the front propeller shaft center bearing
support from the hanger.
19. Remove the front propeller shaft.
20. Clean all parts with an approved solvent.
21. Inspect for proper installation and uniform seating
of all universal joint bearing cups.
22. Inspect the intermediate propeller shaft to rear
propeller shaft slip yoke splines for twisting
or wear.
23. Inspect the inside of the rear propeller shaft slip
yoke for spline twisting or wear.
24. Inspect the front and rear center bearing support
rubber insulators for deterioration or separation
from the support frame work.
25. Inspect the propeller shaft assemblies for damage.
Installation Procedure
1. Install the front propeller shaft to the yoke.
• Make sure the reference marks are aligned.
• Support the front propeller shaft.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the bolts and retainers to the yoke. Maintain
alignment.
Tighten
Tighten the bolts to 20 N-m (26 Ib ft).
3. Install the intermediate propeller shaft to the front
propeller shaft yoke while maintaining alignment
and supporting the propeller shaft.
4. Install the bolts and retainers.
Tighten
• Tighten the bolts to 35 N-m (26 Ib ft)
• Tighten the nuts to 35 N-m (26 Ib ft)
5. Install the rear center bearing support to the
hanger.
6. Align the center bearing support 90 degrees to
both the front and intermediate propeller shaft
center lines.
7. Inspect for proper installation and uniform seating
of all universal joint bearing cups.
8. Inspect the intermediate propeller shaft to rear
propeller shaft slip yoke splines for twisting
or wear.
9. Inspect the inside of the rear propeller shaft slip
yoke for spline twisting or wear.
10. Inspect the front and rear center bearing support
rubber insulators for deterioration or separation
from the support frame work.
11. Inspect the propeller shaft assemblies for damage.
12. Install the bolts and washers.
13. Install the nuts while supporting the rear
propeller shaft.
Tighten
Tighten the nuts to 35 N-m (26 Ib ft).
14. Install the rear propeller shaft to the rear axle
pinion flange while making sure the reference
marks are aligned.
15. Install the bolts and retainers.
Center Bearing Replacement
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the rear propeller shaft. Refer to Propeller
Shaft Replacement - Two-Piece or Propeller Shaft
Replacement - Three-Piece.
3. Remove the front or intermediate propeller shaft.
4. Remove the center bearing.
• Stand the propeller shaft on end in press with
the center bearing supported by press bars.
• Press the propeller shaft down and off
the center bearing.

1236

installation Procedure
1. Install the center bearing onto the propeller shaft
by pressing the center bearing onto the shaft
using a press.
2. Install the front or intermediate propeller shaft.
3. Install the rear propeller shaft. Refer to Propeller
Shaft Replacement - Two-Piece or Propeller Shaft
Replacement - Three-Piece.
N otice: Refer to Fastener Notice in Cautions and
Notices.
Important: The center bearing must be aligned in
order to prevent damage to the propeller shaft
assembly. When bolting the center bearing in place,
be sure to keep it perpendicular (90 degrees plus
or minus 1 degree) to the propeller shaft.
4. Install the center bearing.
Tighten
Tighten the center bearing nuts to
35 N-m (26 Ib ft).
5. Remove the safety stands and lower the vehicle.
Universal Joints Replacement (Nylon
Injected Ring Type)
Disassembly Procedure
Tools Required
• J 9522-3 Universal Joint Bearing Separator
• J 9522-5 Universal Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a
vise. Clamping could dent or deform the tube causing
an imbalance or unsafe condition. Always clamp
on one of the yokes and support the shaft horizontally.
Avoid damaging the slip yoke sealing surface. Nicks
may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with
the table of a press.
2. Mark the propeller shaft as to which end is the
transmission end and which end goes to the
rear axle.
3. Place the universal joint so that the lower ear of
the yoke is supported on a 30 mm (1 1/8 in)
socket.
4. In order to shear the plastic retaining ring on the
bearing cup, place J 9522-3 on the open horizontal
bearing cups and press the lower bearing cup
out of the yoke ear.
5. If the bearing cup is not completely runnion seats
freely into the bearing cup.
6. With the trunnion seated in the bearing cup press
the bearing cup into the yoke until it is flush with
the yoke ear.
7. Rotate the propeller shaft and press the opposite
bearing cup out of the yoke
8. Mark the orientation of the slip yoke to the tube
for proper reassembly.
9. Remove the cross from the yoke.
10. Remove the remaining universal joint parts from
the yoke. If you are replacing the front universal
joint, remove the bearing cups in the slip yoke
in the same manner.
11. Inspect the retaining ring grooves for plastic.
12. Inspect the bearing cup bores in the yoke ears for
burrs or imperfections.
13. Clean the remains of the sheared plastic bearing
retainers from the grooves in the yoke.
14. The sheared plastic may prevent the bearing cups
from being pressed into place and thus prevent
the bearing retainers from being properly seated.
Assembly Procedure
1. Remove the bearing cups from the universal joint.
2. Use you finger in order to coat the needle
bearings in the bearing cup with a thin layer
of chassis grease.
3. Assemble one bearing cup part way into one side
of the yoke.
4. Turn the yoke ear toward the bottom.
5. Assemble the cross into the yoke so the trunnion
seats freely into the bearing cup.
6. With the trunnion seated in the bearing cup press
the bearing cup into the yoke until it is flush with
the yoke ear.

7. Assemble the opposite bearing cup part way into

the yoke ear.
8. Make sure that the trunnions are started straight
and true into both bearing cups.
9. Press the opposite bearing cup into the yoke ear
while working the cross all the time in order to
check for free unbinding movement of the
trunnions in the bearing cups.
Important: If there seems to be a hangup or binding,
stop pressing, and check the needle bearings for
misalignment in the bearing cup.
10. Press the bearing cup into the yoke until the
bearing retainer groove clears the inside of
the yoke.

1224

11. Assemble the bearing retainer in the retainer

groove.
12. Continue pressing until both retainers can be
snapped into place.
 13. If seating the retainer is difficult, spring the yoke
slightly with a firm blow from a dead blow hammer.
14. It may be necessary to lubricate the snap ring with
a slight amount of chassis grease so it seats in
the bearing cup groove.

1226

Universal Joints Replacement (External

Snap Ring Type)
Disassembly Procedure
Tools Required
• J 9522-3 Universal Joint Bearing Separator
• J 9522-5 Universal Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a
vise. Clamping could dent or deform the tube causing
an imbalance or unsafe condition. Always clamp
on one of the yokes and support the shaft horizontally.
Avoid damaging the slip yoke sealing surface. Nicks
may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with
the table of a press.
2. Mark the propeller shaft in order to show which
end connects to the transmission and which end
goes to the rear axle.
3. Disassemble the snap rings by pinching the ends
together with a pair of pliers.
4. If the ring does not readily snap out of the groove
in the yoke, tap the end of the cup lightly in order
to relieve the pressure from the ring.
5. Place the universal joint so that the lower ear of
the yoke is supported on a 30 mm (1 1/8 in)
socket.
 6. Place J 9522-3 on the open horizontal bearing
cups and press the lower bearing cup out of the
yoke ear.
7. If the bearing cup is not completely removed, lift
the cross and insert J 9522-5 between the seal
and bearing cup being removed and continue
pressing it out of the yoke.
8. Rotate the propeller shaft and press the opposite
bearing cup out of the yoke.
9. Mark the orientation of the slip yoke to .the tube
for proper reassembly.
10. Remove the cross from the yoke.
11. Remove the remaining the universal joint parts
from the yoke.
12. If the front universal joint is being replaced,
remove the bearing cups in the slip yoke in
the same manner.
13. I nspect the retaining ring grooves for dirt,
corrosion, or pieces of the old ring.
14. Inspect the bearing cup bores for burrs or
imperfections.
15. Clean the retaining ring grooves. Corrosion, dirt,
rust, or pieces of the old retaining ring may
prevent the bearing cups from being pressed into
place or prevent the bearing retainers from
being properly seated.
Assembly Procedure
1. Remove the bearing cups from the universal joint.
2. Use your finger in order to coat the needle
bearings in the bearing cup with a thin layer
of chassis grease.
3. Assemble one bearing cup part way into one side
of the yoke. Turn the yoke ear toward the bottom.
4. Assemble the cross into the yoke so that
the trunnion seats freely into the bearing cup.
 5. With the trunnion seated in the bearing cup, press
the bearing cup into the yoke until it is flush with
the yoke ear.
6. Install the opposite bearing cup part way into the
yoke ear.
7. Make sure that the trunnions are started straight
and true into both bearing cups.
8. Press the opposite bearing cup into the yoke ear
while working the cross all the time in order to
check for free unbinding movement of the
trunnions in the bearing cups.
Important: If there seems to be a hang up or binding,
stop pressing, and check the needle bearings for
misalignment in the bearing cup.
9. Press the bearing cup into the yoke until the
bearing cup retainer groove is visible over the
top of the bearing cup.

10. Assemble the bearing retainer in the retainer

groove.
11. Continue pressing until both retainers can be
snapped into place.

12. If the retainer is difficult to seat, the yoke can be

sprung slightly with a firm blow from a dead blow
hammer.
13. It may be necessary to lubricate the snap ring
with a slight amount of chassis grease so that
the snap ring seats in the bearing cup groove.
Description and Operation
Propeller Shaft Description Vehicles with two or more propeller shafts use a
center bearing. The center bearing is usually near the
Propeller shafts transmit torque from the transmission rear of the front propeller shaft. The slip joint is at
to the rear axle. The number of propeller shafts the forward end of the rear propeller shaft.
varies with the vehicle wheel base combination of
transmission, transfer case, (front drive), and rear axle
equipment. Universal Joint Description
Propeller shafts have universal joints at each end in
order to accommodate angle variations between
the transmission and rear axle, and the rear axle
position caused by suspension motion. All propeller
shafts are the balanced tubular type.

1237

Universal joints are designed to handle the effects of

various loadings and rear axle windup during
acceleration and braking. Within the designed angle
variations, the universal joint operates efficiently
and safely. When the design angle changes or is
exceeded, the operational life of the joint may
For a one-piece propeller shaft, a splined slip joint
decrease.
connects the driveline to the transmission.
The trunnion bearings used in universal joints are the
needle roller type. Round bearing cups hold the
needle rollers in place on the trunnions. Either snap
rings or injected plastic hold the bearing cups
in the yokes.
The Original Equipment Manufacturer (OEM) universal
joints are lubricated for life and cannot be lubricated
on the vehicle. A service kit which consists of a spider
with bearing assemblies and snap rings may be
installed if a universal joint becomes worn or noisy. If
it is necessary to repair a universal joint, you must
remove the propeller shaft from the vehicle. Avoid
jamming, bending, or over-angulating any parts of the
propeller shaft assembly. Avoid damaging the
propeller weld yokes and slip yoke ears upon
installation or removal of U-joints.

156382

For two-piece and three-piece propeller shafts, a fixed

yoke connects the driveline to the transmission.
Center Bearing Description Special Tools and Equipment

1236

Center bearings support the driveline when using two

or more propeller shafts. The center bearing is a
ball bearing mounted in a rubber cushion that attaches
to a frame crossmember. The manufacturer
prelubricates and seals the bearing. The cushion
allows vertical motion at the driveline and helps isolate
the vehicle from vibration.
Wheel Drive Shafts
Specifications
Fastener Tightening Specifications

Fastener Tightening Specifications

Specification
Application Metric English
Small Seal Retaining Clamp 136 N-m 1001b. ft.
Visual Identification
Disassembled Views
Halfshaft Disassembled View

17'

Legend

(1) Tripot Housing Assembly (10) CV Joint Boot

(2) Spacer Ring (11) Swage Ring
(3) Tripot Joint Spider Assembly (12) Race Retaining Ring
(4) Swage Ring (13) Ball
(5) Tripot Joint Boot (14) CV Joint Inner Race
(6) Small Boot Retaining Clamp (15) CV Joint Cage
(7) Halfshaft Boot Cover (Optional) (16) CV Joint Outer Race
(8) Halfshaft Bar (17) Deflector Ring
(9) Small Boot Retaining Clamp
Repair Instructions
Deflecto r Ring Replacement
Disassembly Procedure
1. Inspect the deflector ring (1).
2. Replace the deflector ring (1) if the deflector
ring (1) is damaged.
3. Use a hammer and a brass drift to tap the
damaged deflector ring (1) off of the CV joint.
4. Discard the deflector ring (1).

Assembly Procedure
Tools Required
• 3 inch or 4 inch pipe coupling
• 12 mm x 12 mm steel plate with a 28 mm hole
drilled in the center. The plate must be at least
3 mm thick.
• M24 x 2.0 nut
1. Put the new deflector ring (1) into position on the
CV joint.
2. Put the 3 inch or 4 inch pipe coupling against the
deflector ring (1). Put the 12 mm x 12 mm steel
plate over the pipe. The halfshaft bar (2) will
protrude through the 28 mm hole in the steel plate

212015
 3. Install the M24 x 2.0 nut on the halfshaft bar.
Tighten the M24 x 2.0 nut until the deflector
ring (1) bottoms against the CV joint.
Important: If the tripot end of the halfshaft assembly
does not require service, follow the directions for
the installation of the halfshaft boot cover; refer
to Wheel Drive Shafts Boot Cover Replacement.
4. Remove the M24 x 2.0 nut, the 12 mm steel plate
and the 3 inch or 4 inch pipe coupling.

Inner Joint and Seal Replacement

Disassembly Procedure
Too l s Required
J 8059 Snap Ring Pliers
Notice: With removal of the halfshaft for any reason,
the transmission sealing surface (the tripot
male/female shank of the halfshaft) should be
inspected for corrosion. If corrosion is evident, the
surface should be cleaned with 320 grit cloth or
equivalent. Transmission fluid may be used to clean
off any remaining debris. The surface should be wiped
dry and the halfshaft reinstalled free of any buildup.
1. Use a hand grinder in order to cut through
the swage ring (2). Do not damage the tripot
housing (1).
2. Remove the tripot housing (1) from the halfshaft.
3. Wipe the grease off of the tripot assembly
roller bearings and the tripot housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to
assembly.
Important: Handle the tripot spider assembly with
care. Tripot balls and needle rollers may separate
from the spider trunnion if the tripot balls and needle
rollers are not handled carefully.
6. Use side cutters to cut away the small boot clamp.
7. Spread the spider spacer ring (2) with J 8059
(or equivalent).

221915

8. Remove the following items from the halfshaft bar:

8.1. The spacer ring (1)
8.2. The spider assembly (2)
8.3. The tripot boot (3)
9. Clean the halfshaft bar (4). Use a wire brush in
order to remove any rust in the boot mounting
area (grooves).
10. Inspect the needle rollers, needle bearings, and
trunnion. Check the tripot housing for unusual
wear, cracks, or other damage. Replace any
damaged parts.

214037

Assembly Procedure
• J 35910 Seal Clamp Tool
• J 36652 Split Plate Swage Clamp (K10 models)
• J 36652 Split Plate Swage Clamp (K20/K30
models)
1. Place the new small boot clamp (2) onto the small
end of the joint boot (1). Slide the joint boot (1)
and small boot clamp (2) onto the halfshaft bar.
2. Position the small end of the joint boot (1) into the
joint boot groove (3) on the halfshaft bar.

386688
 3. Secure the small boot clamp (1) with J 35910
(or equivalent), a breaker bar, and a torque
wrench.
Tighten
Tighten the small boot clamp (1) to
136 N-m (100 Ib ft).
4. Check the gap dimension on the clamp ear.

important: You must assemble the CV joint with the

convolute retainer in the correct position, as illustrated.
7848076 The CV joint boot will be damaged if the CV joint
assembly does not meet the specified dimension.
5. Install the convolute retainer over the inboard joint
boot, being sure to capture three convolutions.

6. Install tripot spider assembly (3) onto the halfshaft

bar (2) with the counterbore towards the end of
the halfshaft bar (2).
7. Install the spacer ring (1) in the groove at the end
of the halfshaft bar (2).
8. Push the spider assembly (3) back toward the end
of the halfshaft bar (2) until the spacer ring is
covered by the spider assembly (3) counterbore.
9. Pack the tripot boot and the tripot housing with
the grease supplied in the kit. The amount of
grease supplied in this kit has been pre-measured
for this application.

212035
10. Reassemble the tripot housing (1) and the tripot
boot using the following procedure:
10.1. Pinch the swage ring (2) slightly by hand
in order to distort it into an oval shape.
10.2. Slide the distorted swage ring (2) over the
large diameter of the boot.
10.3. Place the tripot housing (1) over the spider
assembly (3).
10.4. Install the boot onto the tripot housing (1).
10.5. Align the tripot boot (1), with the swage
ring (2) in place, over the flat area on the
tripot housing (1).

212048

11. Mount J 36652 in a vise.

12. Install the bottom half of the split-plate swage
clamp. For K10 models, use J 36652.
13. For K20/K30 models, use J 36652.

14. Check the inboard stroke position.

• Use measurement A for the K10 models.
• Use measurement B for the K20 and
K30 models.

214960
 15. Position the inboard end (tripot end) of the
halfshaft assembly in J 36652.
16. Install the top half of the proper size tool on the
lower half of the tool. For K10 models, use
J 36652.
17. For K20/K30 models, use J 36652.
18. Align the swage ring (2) and the swage ring clamp.
19. Insert the bolts.
Tighten
Hand tighten the bolts in J 36652 until the bolts
are snug.
20. Align the following during this procedure:
• The tripot boot (3)
• The housing (1)
• The swage ring (2)
Tighten
Tighten each bolt 180 degrees at a time.
Alternate between the bolts until both sides
of the top half of J 36652 touch the
bottom half of the J 36652.
21. Loosen the bolts and remove the halfshaft
assembly from J 36652.
22. Remove the convolute retainer from the boot.

214966
Outer Joint and Seal Replacement
Disassembly Procedure
Tools Required
J 8059 Snap Ring Pliers
1. Place protective covers over the vise jaws. Place
the halfshaft in the vise.

2. Use a hand grinder to cut through the swage

ring (2). Do not damage the GV joint outer
race (1).
3. Use side cutters to cut off the small boot
clamp (4).

4. Slide the boot (5) down the halfshaft bar (4) and
away from the CV joint outer race (1). Wipe all
grease away from the face of the CV joint.
5. Find the halfshaft bar retaining snap ring (3),
which is located in the inner race (2). Spread
the snap ring ears apart using J 8059
(or equivalent).
6. Pull the CV joint (1) and the CV joint boot (5) from
the halfshaft bar (4). Discard the old CV joint
boot (5).

212684
 7. Place a brass drift against the CV joint cage (1).
8. Tap gently on the brass drift with a hammer in
order to tilt the cage (1).
1 9. Remove the first chrome alloy ball (2) when the
CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction
to remove the opposing chrome alloy ball (2).
11. Repeat this process to remove all six of the balls.

211933

12. Pivot the CV joint cage (4) and the inner race
90 degrees to the center line of the outer race (1).
At the same time, align the cage windows (3)
with the lands of the outer race (2).
13. Lift out the cage (4) and the inner race.

214946

14. Remove the inner race (1) from the cage (2) by
1 rotating the inner race (1) upward.
15. Clean the following items thoroughly with cleaning
solvent. Remove all traces of old grease and any
contaminates.
15.1. The inner and outer race assemblies
15.2. The CV joint cage
15.3. The chrome alloy balls
16. Dry all the parts.
17. Check the CV joint assembly for unusual wear,
cracks, or other damage.
18. Replace any damaged parts.
19. Clean the halfshaft bar. Use a wire brush to
remove any rust in the boot mounting area
(grooves).

214947
Assembly Procedure
• J 35910 Seal Clamp Tool
• J 36652 Split Plate Swage Clamp (K10 models)
• J 36652 Split Plate Swage Clamp (K20/K30
models)
1. Inspect all of the parts for unusual wear, cracks,
or other damage. Replace the CV joint assembly
if necessary.
2. Put a light coat of the recommended grease on
the inner (6) and the outer race (8) grooves.

214951

3. Hold the inner race (1) at 90 degrees to the

centerline of the cage (2).
4. Align the lands of the inner race (1) with the
windows of the cage (2).
5. Insert the inner race (1) into the cage (2), by
rotating the inner race (1) downward.

6. Insert the cage (4) and inner race into the outer
race (1).

214946
 7. Place a brass drift against the CV joint cage (1).
8. Tap gently on the brass drift with a hammer in
order to tilt the cage (1).
9. Install the first chrome alloy ball (2) when the
CV joint cage (1) tilts.
10. Tilt the CV joint cage (1) in the opposite direction
to install the opposing chrome alloy ball (2).
11. Repeat this process in order to install all six of
the balls.

211933

12. Pack the CV joint boot (1) and the CV joint

assembly with the grease supplied in the kit. The
amount of grease supplied in this kit has been
pre-measured for this application.
13. Place the new small boot clamp (2) onto the
CV joint boot (1).
14. Slide the CV joint boot (1) onto the halfshaft bar.
15. Position the small end of the CV joint boot (1)
into the joint boot groove (3) on the halfshaft bar.

386688

16. Secure the small boot clamp (1) using J 35910 (or
equivalent), a breaker bar, and a torque wrench.
Tighten
Tighten the small clamp (1) to 136 N-m (100 Ib ft).
Check the gap dimension on the clamp ear.

214026
17. Pinch the new swage ring (2) slightly by hand to
distort it into an oval shape.
18. Slide the distorted swage ring (2) over the large
diameter of the boot (1).
Important: Be sure that the retaining ring side of the
CV joint inner race faces the halfshaft bar (3)
before installation.
19. Slide the CV joint (4) onto the halfshaft bar (3).
The retaining snap ring inside of the inner race
engages in the halfshaft bar groove with a
click when the CV joint (4) is in the proper position.
20. Pull on the CV joint (4) to verify engagement.
21. Slide the large diameter of the CV joint boot (1),
with the large swage ring (2) in place, over the
outside edge of the CV joint outer race (4).

212006

22. Clamp the CV joint boot (2) tightly to the CV joint

outer race (1) with the large swage ring (4), using
the following procedure:
22.1. Mount J 36652 in a vise.
22.2. Install the bottom half of the split-plate
swage clamp. For K10 models, use
J 36652.
22.3. For K20/K30 models, use J 36652.
22.4. Position the CV joint end (outboard end)
of the halfshaft assembly in the bottom
half of J 36652.

23. Align the following during this procedure:

• The CV joint boot (3)
• The CV joint assembly (1)
• The swage ring (2)
24. Install the top half of J 36652 onto the lower half
of the tool, over the CV joint boot (3) and the
CV joint assembly (1).
25. Align the swage ring (2) and the swage ring clamp.
26. Insert the bolts into J 36652. Hand tighten the
bolts until the bolts are snug.
Tighten
Tighten each bolt 180 degrees at a time. Alternate
between the bolts until both sides of the top
half of J 36652 touch the bottom half of the tool.
27. Loosen the bolts and remove the halfshaft J 36652-1
(J 36652-98)
assembly from J 36652.

214033
 Wheel Drive Shafts Boot Cover
Replacement
Disassembly Procedure
1. Use side cutters to cut the halfshaft boot cover
clamps (2) and the nylon strap (1).
Important: If the halfshaft boot cover will be reused,
do not damage the halfshaft boot cover while removing
the clamps.

2. Slide the halfshaft boot cover (1) off of the

halfshaft, over the CV joint end.
3. Check the halfshaft boot cover (1) for rips, tears,
worn spots or other damage. Reuse the halfshaft
boot cover (1) if there is no damage visible.

Assembly Procedure
Tools Required
J 41187 Band-it Type Tool
1. Insert new clamps (3) into the original halfshaft
boot cover (1) (if you are reusing the original
halfshaft boot cover.
2. Slide the halfshaft boot cover (1) onto the halfshaft
assembly (2), starting at the outboard
(CV joint) end.

212067
 3. Align the inboard clamp (2) on the inboard
joint (1). Align the boot cover seam so the seam
is straight.

212079

Important: Tighten the boot cover clamp (1) as tight

as possible without deforming the retaining clip.
Clamps that are not tight enough allow the cover to
slide upon the joint. This causes shortened service life,
4. Use J 41187 in order to tighten the inboard
boot cover clamp (1).

214971

5. Rotate J 41187 toward the clip in order to bend

the band onto the clip.
6. Pull on the tool’s cutting handle in order to cut off
the excess band.
 7. Pound the band flat between the latch tabs. Peen
the latch tabs over in order to lock the band into
position.

8. Twist the halfshaft boot cover (1):

• K10 = 180 degrees
• K20/K30 = 90 degrees
Important: Be sure that the inboard tab of the
halfshaft boot cover (1) is 180 degrees opposite the
outboard tab of the halfshaft boot cover (1) before
proceeding.
9. Position the outboard end of the halfshaft boot
cover (1) over the CV joint (2) flat.

Important: Tighten the boot cover clamp (1) as tight

as possible without deforming the retaining clip.
Clamps that are not tight enough allow the cover to
slide upon the joint. This causes shortened service life.
10. Use J 41187 in order to tighten the outboard
cover clamp (1).
11. Rotate J 41187 toward the clip in order to bend
the band onto the clip.
12. Pull the tool’s cutting handle in order to cut off the
excess band.

13. Pound the band flat between the latch tabs. Peen
the latch tabs over in order to lock the band into
position.

14. Gather the halfshaft boot cover material at the

center. Wrap the halfshaft boot cover (1) tightly
with the nylon strap (2) provided in the kit.

212099
Special Tools and Equipment
Illustration Tool Number/ Description

J 8059
Snap Ring Pliers

J 35910
Eared Seal Clamp

J 36652
Split Plate Swage Clamp

J 41187
Band-it type tool
Front Drive Axle
Specificatio ns
_________ Fastener Tightening Specifications
Specification
; Appl i cat i on IVletrsc English
Axle Shaft Tube to Carrier Bolts 40 N-m 30 Ib ft
Brake Pipe Support Bracket Nut 18 N-m 131b ft
Carrier Frame Screws 22 N-m 161b ft
Carrier Mounting Bolts and Nuts 95 N-m 70 Ib ft
Drive Axle (Halfshaft) Nut at Front Hub 225 N-m 1651b ft
Drive Axle (Halfshaft) Bolts 78 N-m 58 Ib ft
Electric Motor Actuator 20 N-m 15 Ib ft
Engagement Switch 20 N-m 15 1b ft
Front Differential Carrier Shield Bolts 34 N-m 25 Ib ft
Lower Shock Absorber Mounting Nut 73 N-m 541b ft
Outer Tie Rod Nut 62 N-m 46 Ibft
Plug, Drain and Fill 33 N-m 241b ft
RH Axle Tube to Frame Nuts 95 N-m 70 Ib ft
Stabilizer Bar Clamp to Frame Bolts 33 N-m 24 Ib ft
Universal Joint Clamp Bolts 20 N-m 15 Ibft
Upper Control Arm Stud Nut 100 N-m 75 Ib ft

Lubrication Specifications
Specification
Application Metric English
K1 and K2 Models-Fill to Level of the Filler Plug Hole 1.66 liters 3.5 pints
K3 Models-Fill to Level of the Filler Plug Hole 1.85 liters 3.9 pints
Type Recommended SAE 80W-90 GL5 Gear Lubricant
(SAE 80W GL5 in Canada)

GM SPO Group Numbers

Application GM SPO Group Number
Front Axle, Axle Kit, Shaft and Shaft Kit 6.056
Front Axle Bearing, Bolt, Cover, Deflector, Nut, Ring, Seal, Shim, Sleeve, Spacer and
Washer 6.056

Front Drive Axle Shifter/Lock Actuator, Clip, Connector, Fork, Ring, Rivet, Shaft, Spring
6.058
and Washer
Diagnostic Information and Procedures
Noise Diagnosis (Causes of Noise) Tire Noise
Any gear-driven unit produces a certain amount of Tire noise may easily be mistaken for axle noise. Tire
noise that is normal and that conventional repairs or noise changes with different road surfaces; axle
adjustment cannot eliminate. Slight noise that is heard noise does not. Temporarily inflating all tires to
only at a certain speed or under unusual or remote 345 kPa (50 psi) pressure, for test purposes alters the
conditions is acceptable. For example, this noise tends noise caused by tires only materially, but does not
to reach a peak at speeds from 60 to 100 km/h affect noise caused by the axle. Axle noise usually
(40 to 60 mph) depending upon road and load stops when coasting at speeds under 30 miles
conditions, or upon gear ratio and tire size. Noise of per hour. Tire noise still continues with lower tone as
this kind does not indicate trouble in the axle the vehicle speed reduces.
assembly. Engine and Transmission Noises
When an axle is suspected of being noisy, make a In order to determine which unit causes the noise,
thorough test in order to determine whether the noise take note of approximate vehicle speeds and
originates in the tires, road surface, wheel bearings, conditions under which the noise is most pronounced.
engine, transmission, propeller shaft, or axle assembly. Then stop the vehicle in a quiet place in order to
The following procedures will help locate the source stop interfering noises. With the transmission in
of the noise: Raising tire pressure in order to eliminate neutral, run the engine slowly up and down the engine
tire noise (although this will not silence tread noise speeds corresponding to the vehicle speed at which
of mud and snow tires), listening for the noise on the noise was most pronounced. If a similar noise
varying road surfaces, and listening for noise is produced with the vehicle standing still, the engine
at varying speeds such as drive, float, and coast or transmission is the cause, not the axle.
conditions.
Wheel Bearing Noise
Noise Diagnosis (Determining A brinelled wheel bearing causes a knock or click
Type of Noise) approximately every two revolutions of the wheel, since
the bearing rollers do not travel at the same speed
Road Noise as the axle and wheel. With the wheels jacked up, spin
Driving on certain road surfaces, such as brick or the wheels by hand while listening at the hubs for
rough-surfaced concrete, causes noise which may be evidence of a rough or brinelled wheel bearing or loose
mistaken for tire or rear axle noise. Driving on a bearings.
different type of road, such as smooth asphalt or dirt,
will quickly show whether the road surface is the
cause of noise. Road noise usually is the same in drive
as in coast.
Gear Noise Another cause of hypoid gear fracture is extended
overloading of the gear set, which produces fatigue
fracture, or shock loading, and can result in sudden
failure.

There are two basic types of gear noise. The first type
is produced by broken, bent, or forcibly damaged
156776
gear teeth (1), which is usually quite audible over the
entire speed range, and presents no difficulty in The second type of gear noise pertains to the mesh
diagnosis. For example, hypoid gear tooth scoring pattern of the gear teeth (2). This form of abnormal
generally results from the following: insufficient gear noise is recognizable because it produces
lubricant, improper break-in, wrong lubricant, a cycling pitch (whine) and is pronounced in the speed
insufficient gear backlash, improper ring and pinion range at which it occurs, appearing under either
alignment, or loss of drive pinion nut torque. The drive, float, or coast conditions. Gear noise tends to
scoring progressively leads to complete erosion of the peak in a narrow speed range or ranges and will tend
gear tooth or gear tooth pitting and then eventual to remain constant in pitch. Bearing noise varies in
fracture if the initial scoring is not corrected. pitch with vehicle speeds.
Front Drive Axle Diagnosis (Clicking Noise in Turns)
Checks Action
DEFINITION: A clicking noise occurs when driving the vehicle at varying speeds.
Worn out or damaged CV jo int Replace the CV joint.

Front Drive Axle Diagnosis (Clunk Accelerating from Coast)

Checks Action |
DEFINITION: A clunking noise occurs when accelerating the vehicle from coast.
Loose CV joint to output shaft bolts Tighten the output shaft bolts.
A damaged inner CV joint Replace the inner CV joint.

Front Drive Axle Diagnosis (Shudder or Vibration)

Checks Action
DEFINITION: A shudder or vibration occurs when accelerating the vehicle.
An excessive CV joint angle Repair the CV joint angle
Worn or damaged CV joints Replace the CV joints.
Sticking spider assembly Lubricate or replace the inner CV joint.
(inner CV joint)
Sticking joint assembly Lubricate or replace the outer CV joint.
(outer CV joint)
 Front Drive Axle Diagnosis (Vibration at Highway Speeds)
Checks Action
DEFINITION: Vibration occurs while driving the vehicle at highway speeds.
Out of balance or out of round tires Balance or replace the tires.
Front end out of alignment Align the front end.

Front Drive Axle Diagnosis (Front Drive Axle Leaks)

Checks Action
DEFINITION: Fluid leaks from the front drive axle.
Worn differential output seals Repair the seals.
Inspect the mating area between the Reseal the differential housing mating area with RTV sealant.
axle tube and the differential housing.
Inspect the vent hose connector. Replace the vent hose connector.

Four-Wheel-Drive Diagnosis (4WD Will Not Engage)

Checks Action
DEFINITION: Four wheel drive will not engage.
A blown fuse (A/C-HTR fuse) Replace the fuse.
Feed wire to transfer case Repair the open wire.
switch open
The transfer case switch is faulty. Replace the transfer case switch.
The wires to the front axle actuator Repair the open wiring.
are open.
The front axle actuator is faulty. Replace the axle actuator.
The axle is damaged internally. Repair the axle as necessary. Refer to Differential Carrier Overhaul

Four-Wheel-Drive Diagnosis (4WD Does Not Disengage)

Checks Action
DEFINITION: The four-wheel drive will not disengage.
The transfer case switch is faulty. Replace the transfer case switch.
The front axle actuator is faulty. Replace the actuator.
The internal axle is damaged. Repair the internal axle as necessary. Refer to Drive Axle Unit Repair in
Driveline/Axle.

Four-Wheel-Drive Diagnosis (Indicator Light Not Off)

Checks Action
DEFINITION: The four-wheel drive indicator light will not turn off.
The front axle switch is faulty. Replace the front axle switch.

Four-Wheel-Drive Diagnosis (Indicator Light Not On)

Checks Action
DEFINITION: Four-wheel drive engages but the indicator light will not come on.
The bulb is burned out. Replace the bulb.
The front axle switch is faulty. Replace the front axle switch
Electric Motor Actuator Check.
1. Apply 12-volt battery voltage to the actuator. >
terminals.
The p lunger should extend within several seconds.
2. Disconnect the actuator from the power source.
The plunger should retract within several seconds.
3. If the actuator does not operate as specified,
replace the actuator.

Repair instructions
Lubricant Change
Removal Procedure
1. Remove the front differential carrier shield, if
equipped. Refer to Shield Replacement

156585

2. Remove the fill plug (1) and the washer (2).

3. Remove the drain plug (3).
4. Drain the fluid from the differential.
 Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the drain plug (3).
Tighten
Tighten the drain plug (3) to 33 N-m (24 Ib ft).
2. Fill the differential. Refer to Lubrication
Specifications.
3. Install the washer (2) and the fill plug (1).
Tighten
Tighten the fill plug (1) to 33 N-m (24 Ib ft).

4. Install the front differential carrier shield. Refer to

Shield Replacement.

156585

Shield Replacement
Removal Procedure
1. Remove the bolts.
2. Remove the front differential carrier shield,

I
156585
Installation Procedure
1. Install the front differential carrier shield.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the bolts.
Tighten
Tighten the bolts to 34 N-m (25 Ib ft).

156585

Indicator Switch Replacement

Removal Procedure
1. Remove the front differential carrier shield (if
equipped). Refer to Shield Replacement.
2. Remove the electrical connector from the indicator
switch located on the upper left side of the output
shaft tube (5).
3. Remove the indicator switch.

156588

Installation Procedure
1. Coat the indicator switch threads with sealer
GM P/N 1052942.
2. Install the indicator switch to the output shaft
tube (5).
3. Install the electrical connector.
4. Install the front differential carrier shield (if
equipped). Refer to Shield Replacement.
 Electric Motor Actuator Replacement
Removal Procedure
1. Remove the front differential carrier shield (if
equipped). Refer to Shield Replacement.
2. Remove the electrical connector from the actuator.
3. Remove the electric motor actuator by
unthreading.

Installation Procedure
1. Coat the threads of the electric motor actuator
with sealant GM P/N 1052942.
Notice: Refer to Fastener Notice In Cautions and
Notices.
2. Install the electric motor actuator.
Tighten
Tighten the actuator to 20 N-m (15 Ib ft)
3. Install the electrical connector.
4. Install the front differential carrier shield (if
equipped). Refer to Shield Replacement.

372235

Vent Hose Replacement

Removal Procedure
1. Remove the front differential carrier shield (if
equipped). Refer to Shield Replacement.
2. Remove the clamp (3).
Important: Make note of the routing in order to aid in
reassembly.
3. Remove the vent hose (4) from the axle.
4. Remove the bolt (1).
5. Remove the clip (6).
6. Remove the vent hose (7).

156604
Installation Procedure
1. Install the vent hose (4) to the vehicle.
• Route the same way as when removed.
• Make sure the hose is free of kinks and is
routed clear of sharp components.
• Make sure the vent is not plugged.
2. Install the clip (6).
3. Install the bolt (1) and the clamp (2).
4. Install the vent hose (4) to the axle fitting.
5. Install the clamp (3).
6. Install the front differential carrier shield (if
equipped). Refer to Shield Replacement.

Shift Fork Replacement

Removal Procedure
1. Remove the axle shaft (output shaft) and tube
assembly. Refer to Output Shaft, Bearing, and
Tube Replacement (Right Side).
2. Remove the shift shaft (12), damper spring (13),
fork (14) and clip (15) assembly.
3. Remove the spring (16) from the carrier case.
Take care not to dislodge the shim (20) from
the axle shaft (output shaft).

Installation Procedure
1. Install the spring (16) into the carrier case.
2. Install the shift shaft (12), damper spring (13), fork
(14), and clip (15) assembly into the axle tube.
Make sure that the clip fully seats into the groove
on the shift lever.
3. Install the axle shaft (output shaft) and tube
assembly. Refer to Output Shaft, Bearing,
and Tube Replacement (Right Side).

372165
Shift Mechanism Inspection
1. Inspect the carrier connector for damaged splines
and teeth. Replace as required.
2. Inspect the shift fork for wear, scoring, and
damage to the thrust surfaces. Replace as
required.
3. Inspect the differential sleeve and the inner output
shaft for damaged splines and teeth. Replace as
required.
4. Inspect the damper spring for breakage.
5. Inspect the differential actuator and the
engagement switch for damage and frayed wiring.

Output Shaft, Bearing, and Tube

Replacement (Right Side)
Removal Procedure
1. Raise the vehicle and support it using safety
stands.
2. Remove the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement
3. Remove the housing bolts (11) from the carrier.
Important: Keep the open end of the tube up.
4. Remove the axle shaft (output shaft) tube from
the carrier.

Disassembly Procedure
Tools Required
• J 29369-1 Bearing Remover (K2 models)
• J 29369-2 Bearing Remover (K3 models)
1. In a vise, hold the axle shaft (output shaft) tube
by the mounting flange.
2. Remove the sleeve (9).
3. Remove the gear (7).
4. Remove the thrust washer (6).
5. Remove the axle shaft (output shaft) (1). Tap out
the axle shaft with a soft mallet.
6. Remove the seal (3). Pry out the seal with a
screwdriver.
7. Remove the bearing (4). Use the J 29369-1 or the
J 29369-2 and a slide hammer.
8. Clean the parts in a suitable solvent.
9. Clean the gasket surfaces on the axle shaft
(output shaft) tube and carrier housing.
Assembly Procedure
• J 36609 Bearing Installer
• J 36600 Axle Seal Installer (K2 Models)
• J 22833 Seal Installer (K3 Models)
1. Assemble the new bearing (4). Use the J 36609.
2. Apply axle lubricant to the bearing.
3. Install the new seal (3). Use the J 36600 Axle or
the J 22833.
4. Install the axle shaft (output shaft) (1).
5. Place a small amount of grease on the thrust
washer in order to hold it in place.
6. Install the thrust washer (6).
7. Make sure the tabs on the washer align with the
slot in the axle shaft (output shaft) tube.
8. Install the gear (7).
9. Install the sleeve (9).

Installation Procedure
1. Apply sealant GM P/N 12345739 or equivalent to
the carrier sealing surface.
2. Install the axle shaft (output shaft) tube (5) to the
carrier.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the bolts (19).
Tighten
Tighten the bolts to 40 N-m (30 Ib ft).
4. Install the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement.
5. Lower the vehicle.

Axle Shaft and Seal Replacement

Removal Procedure
Tools Required
• J 36600 Seal Installer (K2 Models)
• J 22833 Seal Installer (K3 Models)
• J 23907 Puller/Slide Hammer/Clutch Pilot Bearing
Remover
1. Raise the vehicle and support with safety stands.
2. Remove the differential carrier assembly. Refer
to Differential Carrier Assembly Replacement.
3. Remove the axle shaft (output shaft) (19).
 important: Do not damage the case.
4. Attach a slide hammer with adapter to the axle
shaft (output shaft) and pull the axle shaft from
the case.
5. Remove the deflector (28).
6. Remove the seal (26).
7. Remove the bearing (21). Use the J 23907.
Installation Procedure
Tools Required
• J 36600 Seal Installer (K2 Models)
• J 22833 Seal Installer (K3 Models)
• J 23907 Puller/Slide Hammer/Clutch Pilot Bearing
Remover
• J 22761 Differential Side Bearing Installer
Important: You may need to attach 1/2 inch by
13 inch long extension handle onto the slide hammer
for easier pulling of the bearing.
1. Install the bearing with the square shoulder in.
Use the J 22761.
2. Install the new seal (26). Use the J 36600 or
J 22833.
3. Install the deflector (28).
4. Install the axle shaft (output shaft) (19).
5. Carefully tap the axle shaft (output shaft) (19) into
place with a soft mallet.
6. Install the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement.

Differential Pilot Bearing Replacement

Removal Procedure
Tools Required
• J 34011
• J 33842 Pilot Bearing Installer
1. Remove the axle shaft (output shaft) and tube
assembly. Refer to Output Shaft, Bearing, and
Tube Replacement (Right Side).
2. Remove the shim (20).
3. Remove differential pilot bearing (21). Use the
J 34011.

156588
Installation Procedure
1. Install the shim (20).
2. Install the differential pilot bearing (21). Use the
J 33842.
3. Lubricate the bearing with axle lubricant.
4. Install the axle shaft (output shaft) and tube
assembly. Refer to Output Shaft, Bearing,
and Tube Replacement (Right Side).

Pinion, Flange, and Dust Deflector

Replacement
Removal Procedure
Tools Required
• J 8614-01 Companion Flange Holder and
Remover
• J 36366 Seal Installer
1. Raise the vehicle on a hoist.
2. Remove the propeller shaft from the axle. Refer to
Propeller Shaft Replacement (Front Axle - All
Except NP8) or Propeller Shaft Replacement
(Front Axle - NP8).
3. Tie the propeller shaft to a frame rail or
crossmember.
4. Measure the torque required to rotate the pinion.
Record the torque value for reassembly.

5. Scribe a line (1) on the pinion stem, pinion nut

and the companion flange (2) and record the
number of exposed threads on the pinion stem.
 6. Remove the nut. Use the J 8614-01.
7, Position the J 8614-01 on the flange so that the
four notches on the tool face the flange.

8. Remove the flange. Use the J 8614-01. Use the

special nut and forcing screw.
Important: Carefully pry the seal from the bore. Do
not distort or scratch the aluminum case.
9. Remove the oil seal.
10. Inspect the pinion flange for a smooth oil seal
surface.
11. Inspect the pinion flange for worn drive splines.
12. Replace the pinion flange if necessary.
13. Remove the dust deflector.
• Tap the deflector from the flange.
• Clean up the stake points on the flange.

Installation Procedure
Tools Required
J 36366
• J 8614-01 Companion Flange Holder and
Remover
• J 36366 Seal Installer
Important: Stake the new deflector at three new
equally spaced positions. You must stake the
new deflector in such a way that you do not damage
the seal operating surface.
1. Install the dust deflector on the flange.
Important: Position the oil seal in the bore, then place
the J 36366 over the oil seal. Strike the J 36366
with a hammer until the seal flange seats on the axle
housing surface. Drive the seal in straight, not at
an angle, as this will damage the aluminum housing.
2. Install the oil seal. Use the J 36366.

156671
Notice ; Do not hammer the pinion flange/yoke onto
the pinion shaft. Pinion components may be damaged
if the pinion flange/yoke is hammered onto the
pinion shaft.
3. Install the flange onto the pinion using the
J 8614-01.
4. Place the washer and a new nut on the pinion
threads and tighten the nut to the original
scribed position using the scribe marks and
exposed threads as reference.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Measure the rotating torque of the pinion and
compare this with the rotating torque recorded
earlier.
Tighten
Tighten the pinion nut by small increments until
the torque required to rotate the pinion is
0.35 N*m (3 Ib in) greater than the original torque.
6. Install the propeller shaft. Refer to Propeller Shaft
Replacement (Front Axle - All Except NP8) or
Propeller Shaft Replacement (Front Axle - NP8).
7. Lower the vehicle.

Differential Carrier Bushing Replacement

Removal Procedure
Tools Required
J 36616 Bushing Remover and Installer
1. Remove the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement.
2. Remove the carrier bushing. Use the J 36616.

156679
Installation Procedure
1. Install the carrier bushing. Use the J 36616.
2. Install the differential carrier assembly. Refer to
Differential Carrier Assembly Replacement.

Differential Carrier Assembly Replacement

Removal Procedure
1. Raise the vehicle and support with jack stands.
2. Drain the front axle. Refer to Lubricant Change.
3. Remove the front propeller shaft at the carrier
yoke. Refer to Propeller Shaft Replacement
(Front Axle - All Except NP8).
4. Wire the propeller shaft out of the way.
5. Remove the left and right drive axle (halfshaft).
Refer to Halfshaft Assembly Replacement.
6. Remove the screws (1), nuts (6), and washers (2).
7. Remove the wiring at the axle (5).
8. Remove the vent hose at the axle. Refer to Vent
Hose Replacement
9. Remove the carrier lower mounting bolt.
10. Remove the right side inner tie rod end from the
relay rod. Refer to Tie Rod Replacement
(All Except C3500HD) in Steering Linkage
11. For some models, remove the engine oil filter.
12. Attach a transmission jack to the carrier (5).
13. Remove the upper carrier mounting bolt (6).
14. Remove the carrier from the vehicle.

Installation Procedure
1. Install the carrier to the vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the carrier mounting bolts (6), nuts (2) and
washers (3).
Tighten
Tighten the bolts to 110 N-m (80 Ib ft).
3. Remove the transmission jack.
4. Install the new engine oil filter if your model
required that you remove the engine oil filter.
5. Install the tie rod. Refer to Tie Rod Replacement
(All Except C3500HD) in Steering Linkage

156656
 6. Install the axle tube bolts (1), nuts (6), and
washers (2),
Tighten
• For K2 models tighten the nuts to
100 N-m (75 Ibft).
• For K3 models tighten the nuts to
145 N-m (106 Ibft).
7. Install the vent hose. Refer to Vent Hose
Replacement.
8. Install the wiring.
9. Install the left and right drive axle (halfshaft).
Refer to Halfshaft Assembly Replacement.
10. Install the front propeller shaft to the carrier yoke.
Tighten
Tighten the universal joint clamp bolts to
20 N-m (15 Ibft).
11. Fill the front axle. Refer to Lubricant Change.
12. Add engine oil as necessary. Refer to Approximate
Fluid Capacities in Maintenance and Lubrication.

Halfshaft Assembly Replacement

Removal Procedure
Tools Required
• J 24319-01 Steering Linkage Puller
• J 36605 Front Knuckle Seal Installer
• J 36607 Upper Ball Joint Separator
• J 29193 Steering Linkage Installer (12 mm)
1. Raise the vehicle and support it with safety
stands.
2. Insert a drift or large screwdriver through the
brake caliper into one of the brake rotor vanes
in order to prevent the drive axle (halfshaft) from
turning.
3. Remove the wheel and tire assembly.
 4. Remove the drive axle (halfshaft) hub nut (2) and
washer (3).
5. Loosen, but do not remove, the 6 bolts (1)
securing the inboard C/V joint drive flange to the
output shaft companion flange.
6. Wrap shop towels around both the inner and
outer C/V joint boots in order to avoid damage
to the boots during removal and installation.

156607

7. Remove the wheel speed sensor wire support

bracket (2) from the upper control arm (1) in order
to allow extra travel of the knuckle (all K-models).

156608

8. Remove the wire and the brake line support

brackets (2) from the knuckle on 8600# and
heavier GVWR.
important: Do not reuse the nut.
9. Remove the prevailing torque nut from the outer
tie rod.

156610
 Notice: Do not disengage the joint by driving a
wedge-type tooi between the joint and the knuckle.
This may cause seal damage.
10. Separate the outer tie rod ball stud from the
steering knuckle. Use the J 24319-01.
11. Push the linkage to the opposite side of the
vehicle and secure the outer tie rod up and out of
the way which will provide the needed clearance
in order to remove the drive axle (halfshaft).

12. Remove the lower shock mounting nut, washers,

and bolt.
13. Collapse the shock absorber and secure if
necessary.

156613

14. Remove the stabilizer shaft components as

follows:
14.1. Remove the stabilizer shaft bushing and
bracket.
14.2. Remove the stabilizer shaft bolt, spacer,
and nut assembly at the lower control arm.
Notice: This is required on K vehicles with 8050 Ib
and below GVW rating in order to provide needed
clearance for drive axle (halfshaft) removal.
Caution: A suitable support must be placed under
the lower control arm at the correct location in
order to maintain torsion bar tension before
servicing the wheel drive shaft. Failure to support
the lower control arm at the correct location
will allow the torsion bar tension to release,
damaging suspension components and potentially
resulting in personal injury.
15. Position the floor jack or stand behind the steering
knuckle.
16. Remove the cotter pin from the upper control arm
ball joint stud.
17. Loosen (do not remove at this time) the stud nut
on the upper ball joint stud.
18. Loosen the stud from the knuckle using the
J 36607.
19. Remove the nut.
20. Remove the stud from the knuckle.
Important: Cover the shock mounting bracket and the
ball stud on the lower control arm with a shop towel
in order to prevent possible drive axle (halfshaft) boot
damage during removal and installation.
21. Remove the knuckle assembly using a hammer
and brass drift or equivalent in order to separate
the outer CN joint splined shank from the
knuckle hub.

22. Remove the six bolts (1) from the inboard joint
flange.
• Support the inboard end of the drive axle
(halfshaft).
• Move the knuckle and hub assembly outward
in order to free the splined shank from
the hub.
23. Remove the drive axle (halfshaft) from the
vehicle.
24. For unit repair of the drive axle (halfshaft), refer to
Drive Axle Unit Repair in Driveline/Axle.
I mportant: Wipe the wheel bearing seal area on the
knuckle clean.
25. Inspect the seal for cuts or tears.
26. Lubricate the seal lip.
27. If the seal is cut or tom, inspect the wheel bearing
for damage and replace the seal.
28. Do the following in order to replace the seal:
• Pry the old seal from the knuckle.
• Discard the old seal.
• Lubricate the new seal lip.
• Use the J 36605 in order to install the seal into
the knuckle.
 Installation Procedure
1. Prior to drive axle (halfshaft installation, cover the
shock mounting bracket, lower control arm ball
stud, and all other sharp edges with shop towels
so that the drive axle (halfshaft) boot is not
damaged during assembly.
I mportant: Do not lubricate the drive axle (halfshaft)
splines and knuckle with grease.
2. Insert the outer C/V joint splined shank into the
knuckle hub and secure the inboard C/V joint
flange to companion flange with bolts. Do
not tighten.
3. Install the upper ball joint to the steering knuckle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the stud nut.
Tighten
Tighten the stud nut to 100 N-m (75 Ib ft).
5. Install the cotter pin.
6. Lubricate the upper ball joint until grease appears
at the seal.
7. Install the stabilizer shaft bushing, bracket,
and bolts.
Tighten
Tighten the bolts (5) to 33 N-m (24 !b ft).
8. Install the stabilizer shaft link bolt assembly,
spacer, and nut assembly.
Tighten
Obtain torque by running the nut assembly to the
unthreaded portion of the bolt, then tighten to
18 N-m (13 Ibft).
9. Remove the floor jack or stand from the beneath
the lower control arm.
10. Install the shock absorber to the lower shock
mounting bracket.
11. Install the shock mounting bolt, washer, and nut.
Tighten
Tighten the nut to 73 N-m (54 Ib ft).
12. Install the outer tie rod to the steering knuckle
using the J 29193.
Tighten
Tighten the tool to 54 N-m (40 Ib ft).
13. Install the new outer tie rod prevailing torque nut.
Tighten
Tighten the nut to 62 N-m (46 Ib ft).
14. Install the brake pipe support bracket to the upper
control arm.

156613
Important: Make sure that the brake hose is not
twisted or kinked, or damage to the hose could result.
15. Install the brake pipe support bracket to the
upper control arm.
Tighten
Tighten the nut to 17 N-m (13 Ib ft).
16. Install the hub nut washer (3) and the nut (2).
17. Seat the shank splines in the hub.
18. Insert a drift through the brake caliper in order to
prevent the drive axle from turning.
Tighten
Tighten the inboard flange bolts to
78 N-m (58 Ib ft).
19. Install the hub nut.
Tighten
Tighten the hub nut to 225 N-m (165 Ib ft).
20. Remove the drift. 156607

21. Install the wheels.

22. Remove the safety stands.
23. Lower the vehicle.

Differential Carrier Overhaul

Inspection Procedure
Perform the following checks before disassembling
the axle:
1. Remove the drain plug from the axle.
Drain the axle lubricant.
2. Check the ring gear backlash. Refer to Backlash
Inspection and Adjustment.
This information can be used to determine the
cause of the axle problem. The information
will also help when setting up the shim packs for
locating and preloading the differential case.
3. Inspect the case for metal chips.
Determine the source of the metal chips, such as
a broken gear or bearing cage.
4. Determine the cause of the axle problem before
disassembly, if possible.
Disassembly Procedure
Tools Required
• J 29369-1 Bearing Remover (T, K1 and K2
Models)
• J 29369-2 Bearing Remover (K3 Models)
• J 29307 Slide Hammer
• J 34011 Pilot Bearing Remover
• J 36599 Adjusting Sleeve Wrench
• J 36615 Adjuster Plug Wrench (K3 Models)
• J 8614-01 Pinion Remover
• J 36598 Holding Fixture and Pinion Service Tool
• J 8612-B Pinion Bearing Remover (T, K1 and
K2 Models)
 • J 36606 Inner Pinion Bearing Remover Pinion
Bearing Remover (K3 Models)
• J 22888 Side Bearing Puller
• J 8107-2 Side Bearing Puller Pilot (T, K1 and K2
Models)
• J 36597 Side Bearing Puller Pilot ( K3 ) Side
Bearing Puller Pilot (K3 Models)
• J 36616 Bushing Replacer
• J 2619-01 Slide Hammer
• J 36598 Holding Fixture
1. Remove the differential actuator.
2. Remove the engagement switch.
3. Remove the bolts.
4. Remove the axle tube with the right output shaft.
5. Remove the differential sleeve.
6. Remove the following parts:
• The shift shaft
• The damper spring
• The shift fork
• The shifter shaft ring
7. Remove the spring.
8. Remove the shim.
9. For the T, K1, and K2 models, remove the carrier
connector with the retainer ring.
9.1. Clamp the axle tube in a vise.
Clamp only on the mounting flange,
9.2. Strike the inside of the shaft flange with a
brass hammer in order to dislodge the
carrier connector.
10. For the K3 models, remove the following parts:
• The snap ring
• The washer
• The thrust washer
11. Remove the right output shaft.

12. Remove the seal and the output shaft bearing.

• For the T, K1, and K2 models, use the
J29369-1.
• For the K3 model, use the J 29369-2 or the
J 29307.
13. Remove the output shaft.

14. Use the J 34011 in order to remove the differential

pilot bearing.
 15. Use the J 2619-01 in order to remove the left
output shaft.
J 2619-01 16. Remove the seal.
Pry the seal out with a removal tool.

J 21579

17. Remove the bearings.

• For the T, K1, and K2 models, use the
J 29369-1.
• For the K3 model, use the J 29369-2 or the
J 29307.
18. Remove the bolts.

19. Remove the right side carrier half.

Tap on the cast lugs provided.

205917
20. Remove the differential assembly.
Pry up on the locks.
Pry the right side only on the K3 model.
21. For the K3 model, remove the bolt and the lock.

22. Remove the sleeve(s) and the side bearing cups.

• Turn the sleeve(s) in order to push the bearing
cup(s) out of the bore(s).
• Use the J 36599.
• For the K3 model, remove the sleeve(s) and
side bearing cups only from the right side.

205910

23. For the K3 model, use the J 36615 in order to

remove the adjuster plug with the side bearing
cup and the O-ring seal.
 24. Remove the nut.
Use the J 8614-01 in order to hold the pinion
flange.
25. Remove the washer.
26. Use the J 8614-01 in order to remove the pinion
flange with the deflector.

9225

27. Mount the left carrier case in the J 36598.

For the T, K1, and K2 models, use the adapter
plate J 36598.
28. Use the J 36598 in order to remove the ring and
pinion with the following parts:
• The shim
• The bearing cone
• The spacer
29. Remove the spacer from the pinion.

30. Remove the pinion bearing.

• For the T, K1, and K2 models, use the
J8612-B.
• For the K3 model, use the J 36598 and
a press.
31. Remove the shim.

210154
32. Use the J 36598 in order to remove the
following parts:
J 36598 - 6
• The seal
• The bearing cup
• The cone

33. Use the J 36615 in order to remove the

bearing cup.

210172

34. Remove the side bearings.

• For the T, K1, and K2 models, use the J 8 1 0 7 -3
J 22888 and the J 8107-2.
• For the K3 model, use the J 36597 Side
Bearing Puller Pilot (K3) and a press.
Notice: Do not pry the ring gear from the case. This
will damage the ring gear and the differential case.
35. Remove the ring gear bolts.
The ring gear bolts have left-handed threads.
 36, Remove the ring gear from the differential case.
Drive the ring gear off with a brass drift.

37. For the T, K1, and the K2 models, remove

the pin.
Use a drift and a hammer in order to drive out
the pin.

168052

38. For the K3 model, remove the bolt.

39. Remove the shaft.
40. Remove the differential pinion gears and the
side gears.
40.1. Roll the pinion gears out of the case with
the pinion thrust washers.
40.2. Remove the side gears and the side gear
thrust washers.
Mark the gears and the differential case as
left and right.
40.3. For the K3 model, remove the spacer.
41. Remove the vent plug.
Use a 6-point deep socket.

206945
42. Use the J 36616 in order to remove the bushings.

156679

Inspection Procedure
Thoroughly and carefully inspect all of the drive units
before assembly. Thorough inspection of the parts
for wear or stress and replacement of worn parts will
help prevent costly drive component repair after
the reassembly.
Axle Housing Inspection
1. Inspect the axle housing bore for nicks or burrs
that would prevent the outer diameter of the
pinion seal from sealing. Remove any burrs.
2. Inspect the bearing cup surfaces for nicks or
burrs. Remove any burrs.
3. Replace the housing if any cracks are found.
4. Inspect the housing for the following materials:
• Metal chips
• Dirt
• Rust
5. If the above materials are found, refer to Cleaning
Carrier Components.
Differential Inspection
1. Inspect the pinion gear shaft for unusual wear.
2. Inspect the pinion gear and the side gear teeth for
the following conditions:
• Wear
• Cracks
® Scoring
• Spalling
3. Inspect the thrust washers for wear.
4. Inspect the fit of the differential side gears in the
differential case.
5. Inspect the fit of the side gears on the axle shafts.
6. Inspect the differential case for cracks and
scoring.
7. Inspect all the parts for wear. Replace as
necessary.
 Differential Assembly Installation
Tools Required
• J 36612 Bearing Installer (T, K1, and K2 models)
• J 36613 Bearing Installer Bearing Installer
(K3 model)
• J 36513 Driver Handle
• J 36599 Sleeve Adjusting Wrench
• J 36615 Adjuster Plug Wrench (K3 model)
• J 36603 Side Bearing Cup Installer
1. For the T, K1, and K2 models, use the J 36513
and the J 36612 in order to install the bearings to
the sleeves.
2. For the K3 model, use the J 36613 Bearing
Installer in order to install the adjuster plug.
3. For the K3 model, install the new O-ring seal to
the adjuster plug.

4. For the T, K1, and K2 models, use the and the

J 36599 in order to install the sleeves to the
carrier case.
5. For the K3 model, use the J 36615 in order to
install the right sleeve to the carrier case.
Use the J 36599 in order to install the
adjuster plug.
6. Use the J 36603 with the J 36513 in order to
install the side bearing cups.

206850

7. Install the differential assembly to the carrier

case half.
• Place the differential assembly into the carrier
case half which contains the pinion gear.
• For T, K1, and K2 models, use the J 36599 in
order to turn the left sleeve in until the
backlash is felt between the ring and the
pinion.

205910
 8. For the K3 model, use the J 36615 in order to
turn the adjuster plug in until the backlash is felt
between the ring and the pinion.
9. Remove the carrier case from the J 36599
10. Install the carrier case halves.
Do not use sealer at this time.
If the carrier halves do not make complete
contact, use the J 36599 in order to back out the
right sleeve.
11. Install the bolts.
Tighten
Tighten the bolts to 47 N-m (35 Ib ft).

Cleaning Carrier Components

Cleaning Procedure
1 . Do not steam-clean the drive parts having found
and polished the following surfaces:
• The gears
• The bearings
• The shafts
2 . Disassemble al l of the parts before cleaning.
3. Clean the parts in a suitable solvent.
4. Dry the parts immediately after cleaning.
• Use soft, clean, lintless rags.
• Parts may be dried with compressed air.
• Do not allow the bearings to spin while drying
them with compressed air.

Ring and Pinion Gear Inspection

1. The ring and pinion gears are matched sets and
must be replaced any time a replacement of
either is necessary.
2. Inspect the pinion and the ring gear teeth for the
following conditions:
• Cracking
® Chipping
• Scoring
• Excessive wear
3. Inspect the pinion gear splines for wear.
4. Inspect the pinion flange splines for wear.
5. Inspect the fit of the pinion flange on the
pinion gear.
6. Inspect the sealing surface of the pinion flange for
nicks, burrs, or rough tool marks which will
damage the inside diameter of the pinion seal and
result in an oil leak.
7. Inspect all of the parts for wear and replace as
necessary.
Bearings Inspection
Important:
• When replacing the worn or cracked bearings and
the cups, replace the bearings in sets.
• The low mileage bearings may have very small
scratches and pits on the rollers and the
bearing cups from the initial preload.
Do not replace a bearing for this reason.
1. Inspect the bearings for smooth rotation after
oiling.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for the following
conditions:
• Wear
• Cracks
• Brinelling
• Scoring

Thrust Washers, Shims, and Adjuster

Sleeves
1. Inspect the shims and the thrust washers for
cracks and chips.
The damaged shims should be replaced with an
equally sized service shim.
2. Inspect the adjuster sleeves for damaged threads.
Replace if required.

Pinion Bearing Gup Installation

Tools Required
• J 36598 Holding Fixture and Pinion Service Tool
• J 36598 Adapter Plate (T, K1, K2 models)
Important: At assembly, apply axle lubricant to all of
the following parts:
• The bearings
• The seal lips
• The gears
• The thrust washers
• The bearing surfaces
1. Mount the left carrier case in the J 36598.
For the T, K1, and K2 models, use the
J 36598 adapter plate.
2. Tighten the attaching bolts securely.
3. Install the outer bearing cup.
• For the T, K1, and K2 models, use the forcing
screw and the J 36598.
• For the K3 model, use the J 36598.
4. Install the inner bearing cup.
4.1. Remove the J 36598 or the J 36598 from
the forcing screw.
4.2. Place the pilot J 36598 in the pinion
seal bore.
4.3. Extend the forcing screw through the
pinion bore.
4.4. For the T, K1, and K2 models, install the
J 36598 on the forcing screw.
For the K3 model, install the J 36598 on the
forcing screw.
4.5. Rotate the forcing screw until the installer is
snug against the bearing cup.
4.6. Rotate the tool several times in order to
ensure the bearing cup is not cocked in
the bore.
5. Pull the bearing cup into place with the
forcing screw.
206943

Pinion Depth Adjustment

• J 36601 Pinion Depth Setting Gauge J 36601
• J 29763 Dial Indicator
• J 21777-40 Pinion Setting Gauge Set
1. The pinion depth is adjusted by selecting a shim
of the proper thickness.
2. Lubricate the pinion bearings liberally with axle
lubricant.
3. For the T, K1, and K2 models, assemble the
J 29763 to the proper gauging arm.
4. For the K3 model, assemble the J 29763 to the
proper gauging arm.
5. Install the pinion bearings and hold them in place.
6. For the T, K1, and K2 models, insert the
threaded rod of the J 36601 through the pinion
bearings.
7. Install the proper pilot, washer, and nut.
206851
8. Tighten the nut while holding the threaded rod
with a wrench in order to adjust bearing preload.
8.1. Adjust the nut in order to obtain a
preload of 1.0-1.6 N-m (10-15 Ib in) using
an inch pound torque wrench.
8.2. Rotate the shaft several times in order to
ensure that the bearings are seated.
8.3. Take another measurement.
9. Push the dial indicator downward until the needle
rotates about 3/4 turns.
 10. Tighten the dial indicator in this position.
11. Set the button of the J 36601 on the differential
bearing bore.
12. Rotate the tool slowly back and forth until the dial
indicator reads the lowest point of the bore.
12.1. Set the dial indicator to ZERO .
12.2. Repeat the rocking action to the tool in
order to verify the ZERO setting.

206853

13. After the ZERO setting is obtained and verified,

grasp the gauging arm by the flats and move the
tool button out of the differential side bearing bore.
14. Record the dial indicator reading.
N otice: Proper pinion depth setting is a two-step
procedure. Both procedures must be performed
to ensure proper axle performance and prevent system
damage.
15. Setup dimension arrived at with the indicator is to
. be considered a starting point.
16. Gear tooth pattern check is necessary to fine tune
the pinion depth and may indicate addditional
shim changes to the pinion stem.
16.1. Setup dimension arrived at with the
indicator is to be considered a
starting point.
16.2. Gear tooth pattern check is necessary to
fine tune the pinion depth and may
206859 indicate addditional shim changes to the
pinion stem.
; 16.3. The dial indicator reading is equal to the
required shim size.
17. Remove the tool and the bearing cones.
Pinion Installation
8J 35512 Bearing Installer (T, K1, and K2 Models)
•J 36614 Bearing Installer (K3 Models) J 35512
•J 8614-01 Pinion Flange Remover J 36614
•J 36366 Seal Installer
1.Install the shim to the pinion gear.
Use the proper size shim.
2. For the T, K1, and K2 models, use the J 35512 in
order to install the bearing onto the pinion gear.
3. For the K3 model, use the J 36614 in order to
install the bearing onto the piston gear.
4. Install the new spacer onto the pinion gear.

210203

5. Install the bearing into the case.

6. Install the seal into the case using the J 36366.
J 36366
7. Install the pinion gear, with the bearing and
the spacer, to the case.

8. Install the deflector, the flange, the washer and

the nut using the following procedure:
• Apply PST Sealant GM P/N 1052080 or the
equivalent, to the pinion gear threads and
on both sides of the washer.
• Tighten the nut until no end play is detectable
while holding the flange with the J 8614-01.
• No further tightening should be attempted until
the bearing preload has been checked.
 9. Measure the pinion bearing preload.
9.1. Use an inch-pound torque wrench.
The correct preload is
1.7-2.8 N-m (15-25 Ib in).
9.2. Rotate the pinion witht he torque wrench
and note the reading.
9.3. If the preload torque is below specifications,
continue torquing the pinion nut in small
increments. Check the preload after
each tightening.
Each tightening will increase the bearing
preload by several inch pounds.
If the bearing preload is exceeded, the
pinion will have to be removed, and a new
collapsible spacer installed.
9.4. Once the preload has been obtained, rotate
the pinion several times in order to ensure
the bearings are seated.
9.5. Recheck the preload, and adjust as
necessary.

Differential Case Assembly Assemble

Tools Required
• J 22761 Side Bearing Installer (T, K1, and K2
models)
• J 29710 Side Bearing Installer (K3 model)
• J 8092 Driver Handle
1. Install the thrust washers and the side gears into
the differential case.
If the same gears and the washers are being
used, install the gears and washers to the original
locations.
2. Install the pinion gears.
• Position one pinion gear between the
side gears.
• Rotate the gears until the pinion gear is
directly opposite the opening in the case.
• Place the other pinion gear between the
side gears.
Line up the hole in both pinion gears.
3. Install the thrust washers.
Rotate the pinion gears toward the opening in
order to permit the sliding in of the thrust washers.
4. For the T, K1, and K2 models, install the
shaft and pin.
5. For the K3 models, install the bolt.
6. Install the ring gear onto the differential case.
I mportant: install new bolts. Do not reuse
the old bolts.
7. Install the bolts.
The bolts have left hand threads.
Tighten
Tighten the bolts alternating in progressive steps
to 120 N-m (88 Ibft).
Notice: Refer to Fastener Notice in Caution and
Notices.
8. For the T, K1, and K2 models, use the J 22761 in
order to install the side bearings.
J 8092
9. For the K3 model, use the J 8092 in order to
install the side bearings.

J 22761
J 29710

Carrier Case Assembly

Installation Procedure
1. Bend the lock over the sleeves.
For the K3 model, bend the lock over the sleeves
on the right side.

205910

2. For the K3 model, install the bolt and the lock.

205912
 Removal Procedure
1. Remove the bolts.
2. Remove the right carrier case half.
3. Clean the carrier case and the axle tube sealing
surfaces.
Remove all the grease and the oil.

Installation Procedure
Tools Required
• J 36600 Axle Output Shaft Seal Installer (K1, K2
models)
• J 22833 Output Shaft Seal Installer (K3)
• J 33842 Pilot Bearing Installer
• J 36616 Bushing Replacer Set
1. Apply a bead of sealer GM P/N 105942 or the
equivalent to one carrier case half sealing
surface.
2. Install the right carrier case half.
3. Install the bolts.
Tighten
Tighten the bolts to 47 N-m (35 Ib ft).

4. For the T, K1, and K2 models, use the J 36600

Axle in order to install the left seal. Drive the seal
J 36600 into place with a soft faced hammer.
J 22833 5. For the K3 model, use the J 22833 in order to
install the left seal. Drive the seal into place
with a soft faced hammer.
6. Install the shaft.
Drive in place with a brass hammer.
 7. Use the J 33842 in order to install the bearing to
the output shaft.
8. Install the output shaft to the carrier.

9. Install the vent plug.

Use a small amount of sealer GM P/N 105942 or
the equivalent on the threads.

10. Use the J 36616 in order to install the bushings.

 Backlash Inspection and Adjustment
Tools Required
J 8001 Dial Indicator Set
1. Use the J 36599 in order to tighten the right
sleeve.
Tighten
Tighten the right sleeve to 140 N-m (100 Ib ft).
Notice: Refer to Fastener Notice in Caution and
Notices.

205910

2. For the T, K1, and K2 models, use the J 36599 in

order to tighten the left sleeve.
Tighten
Tighten the left sleeve to 140 N-m (100 Ib ft).
3. For the K3 model, use the J 36615 in order to
tighten the adjuster plug.
Tighten
Tighten the adjuster plug to 140 N-m (100 Ib ft).
4. Mark the location of the adjusting sleeves in
relation to the carrier halves.
Ensure that the notches in the adjusting sleeves
can be counted when turned.
5. Turn the right sleeve OUT two notches.
6. For the T, K1, and K2 models, turn the left sleeve
in one notch.
7. For the K3 model, turn the adjuster plug in
one notch.
8. Rotate the pinion several times in order to seat
the bearings.
Measuring Backlash
1. Install a dial indicator so the button contacts the
outer edge of the pinion flange.
Ensure that the plunger is at a right angle to the
pinion flange.
2. Move the pinion flange through the pinion flange’s
free play while holding the differential carrier.
Record the dial indicator reading.
3. Divide the dial indicator reading by 2 in order to
obtain the actual backlash when using this
method.
A dial indicator reading of 0.16 mm means that
there is actually 0.08 mm backlash.
4. In order to adjust the backlash, use the fo llowing
procedure:
• The gear backlash should be between
0,08-0.25 mm (0,0003-0.010 in) with a
preferred specification of 0.13-0.18 mm
(0.005-0.007 in).
• If the backlash is incorrect, adjust the sleeves
as necessary. Always maintain the one notch
preload on the side bearings.
Example: If necessary to turn the right sleeve
in one notch, then turn the left sleeve out
one notch.
• In order to increase the backlash, turn the left
sleeve in and turn the right sleeve out an
identical amount.
• In order to decrease the backlash, turn the
right s leeve in and turn the left sleeve out
an identical amount.
• Changing the sleeves one notch changes the
backlash about 0.08 mm (0.003 in).
Gear Tooth Contact Pattern Check Testing Procedure
1. Wipe the oil out of the carrier.
Before the final assembly of the differential, a gear
Carefully clean each tooth of the ring gear.
tooth contact pattern check should be performed.
2. Apply gear marking compound sparingly to all ring
A gear tooth contact pattern check is NOT a substitute gear teeth using a medium stiff brush.
for adjusting the pinion depth and the backlash. The When properly used, the area of pinion tooth
gear tooth contact pattern check is a final check contact will be visible when hand load is applied.
in order to verify the correct running position of the 3. Using a torque wrench, apply a load until a torque
ring gear and the drive pinion. Any gear sets which are of 62 N-m (45 Ib ft) is required to turn the pinion.
not aligned properly may be noisy and have a short • A test that is made without loading the
life. With a pattern check, the best contact between the gears will not give a satisfactory pattern.
ring gear and the drive pinion for low noise level • Turn the companion flange with a wrench so
and long life can be ensured. that the ring gear rotates one full revolution.
• Then reverse the rotation so that the ring gear
Gear Tooth Terms rotates one revolution in the opposite direction.
• Excessive turning of the ring gear is not
recommended.
4. Observe the pattern on the ring gear teeth.
Adjustments Affecting Tooth Contact
There are two adjustments, backlash and pinion
depth, which will affect the tooth contact pattern. The
effects of the bearing preloads are not easily seen
on hand loaded teeth pattern tests. Make the
adjustments within specifications before proceeding
with the backlash and the drive pinion adjustments.
Adjust the pinion depth and the backlash as
necessary, in order to obtain the correct pattern.
The pinion depth is adjusted by increasing or
decreasing the shim thickness between the pinion
head and the inner race of the rear bearing. The shim
is used in the differential in order to compensate for
the manufacturing tolerances. Increasing the shim
thickness will move the pinion closer to the centerline
of the ring gear.
7558 The backlash is adjusted by means of the side
bearing adjusting sleeves which move the entire case
The side of the ring gear tooth which curves outward, and the ring gear assembly closer to, or farther
or is convex, is the DRIVE side (4). The concave from the drive pinion. The adjusting sleeves are also
side is the COAST side (3). The end of the tooth used in order to set side the bearing preload. In
nearest center of the ring gear is the TOE end (2). order to increase the backlash, turn the left sleeve in
The end of the tooth farthest away from the center is and turn the right sleeve out an identical amount.
the HEEL end (1). The toe end of the tooth is In order to decrease the backlash, turn the right sleeve
in and turn the left sleeve out an identical amount.
smaller than the heel end.
The contact pattern must be centrally located up and
down on the face of the ring gear teeth.
Axle Tube Assem bly
Assembly Procedure
Too l s Required
• J 36609 Bearing Installer
• J 36600 Seal Installer (T, K1, and K2 models)
• J 36609 Seal Installer (K3 model)
1. Use the J 36609 in order to install the bearing.
Drive into place with a hammer.
2. For the T, K1, and K2 models, use the J 36600 in
order to install the seal.

210234

3. For the K3 models, use the J 36609 in order to I-

install the seal.

206848

4. Install the shaft to the axle tube.

5. Install the washer. Align the tabs with the slots in
the tube.
6. For the T, K1, and K2 models, install the gear
with the retaining ring.
Drive the gear into place with a plastic hammer.
 7. For the K3 model, install the washer and the new
snap ring.
Ensure the snap ring is properly seated in the
groove.

O u tpu t Shaft Shim S electio n

Tools Required
J 34672 Depth Gauge
1. Select the proper size output shaft shim if any of
the following parts were replaced:
• The shaft
• The axle tube
• The output shaft
• The carrier case
• The ring and pinion gears
• The differential case
• The bearings
• For T, K1»and K2 models, the carrier
connector
2. Push on the inner end of the shaft, and move the
shaft outboard as far as it will go. The shaft must
206848
be in this position when measuring dimension A.

3. Use the J 34672 in order to measure dimension A.

• For the T, K1, and K2, install the tube flange
machined surface to the inner surface of the
connector.
• For the K3, install the tube flange machined
surface to the inner surface of the axle
shaft shoulder.

206836
 4. Measure the dimension B.
Install the carrier machined surface to the outer
surface of the output shaft.
5. Subtract the dimension A from the dimension B.
6. The correct shim size will be one size smaller than
the figure obtained in the previous step.
Note the following examples:
• If the figure obtained in step 5 was 3.53 mm,
use a 3.30 mm shim.
• For the T, K1, and K2 models, if the figure
obtained in step 5 was 3.30 mm, use
a 2.70 mm shim.
• For the K3 model, if the figure obtained in
step 5 was 3.30 mm, use a 2.80 mm shim.
7. For the T, K1, and K2 models, shims are available
in the following sizes:
• 1.27 mm
• 1.78 mm
• 2.29 mm
• 2.70 mm
• 3.30 mm
• 3.81 mm
8. For the K3 models, shims are available in the
following sizes:
• 1.80 mm
• 2.30 mm
• 2.80 mm
• 3.30 mm
• 3.80 mm
• 4.30 mm
• 4.80 mm
Alternate Method
Tools Required
J 8001 Dial Indicator
Important: Use this method only if the proper tools for
calculating the shim size are unavailable.
1. Install the original shim to the shaft.
Use the chassis grease in order to hold the shim
in place.
2. Install the assembled axle tube and the shaft to
the carrier.
Do not use sealer at this time.
3. Install the bolts.

206841
 4. Measure the shaft end play using the following
procedure:
4.1. Install the J 8001 or the equivalent on the
axle tube end.
The plunger of the indicator must be at a
right angle to the axle flange.
4.2. Move the shaft back and forth and read the
end play.
The correct end play is 0.03-0.51 mm
(0.001-0.020 in).
4.3. If the end play is incorrect, install a thicker
or thinner shim as needed in order to bring
the end play into the specified range.
4.4. Install the bolts.
4.5. Install the axle tube assembly.

Differential Carrier Final Assembly .

1. Clean the sealing surfaces of the tube and the
carrier assembly.
Remove all the oil and the grease.
2. Install the shim to the output shaft.
Hold the shim in place with grease.
3. Install the sleeve.
4. Install the spring.
5 |nS|a|| following parts to the carrier case:
• The shift shaft
• The damper spring
The dimper spring fits into the shift fork
indentation.
• The shift fork
• The clip assembly
Ensure that the clip is seated in the groove of
206820 the shift shaft.
6. Apply a bead of sealer GM P/N 1052942 or the
equivalent to the tube sealing surface.
7. Install the assembled tube to the carrier assembly.
8. Install the bolts.
Notice: Refer to Fastener Notice in Caution and
Notices.
9. Inspect the shift mechanism operation.
9.1. Insert a drift into the actuator hole in the
axle tube.
9.2. Rotate the axle flange while moving the
shift fork with the drift.
9.3. The shift mechanism should work smoothly,
without binding.
10. Install the actuator.
Apply the sealer GM P/N 1052942 or the
equivalent to the threads.
11. Install the switch.
Apply the sealer GM P/N 1052942 or the
equivalent to the threads.
12. Install the axle lubricant, as specified.
13. Install the drain and fill plugs with sealing washers.
Tighten
• Tighten the actuator bolts to 22 N-m (16 Ib ft).
• Tighten the switch bolts to 5 N-m (45 Ib in).
• Tighten the drain and fill plug to
33 N-m (24 Ib in).

Description and Operation

Front Drive Axle Description
The Front Axle on four-wheel drive model vehicles has
a central disconnect feature that, under most
conditions, allows shifting into and out of four-wheel
drive when the vehicle is in motion. An electric
motor actuator engages the central disconnect feature.
The axle uses a conventional ring and pinion gear
set in order to transmit the driving force of the engine
to the wheels. The differential allows the wheels to
turn at different rates of speed while the axle continues
to transmit, the driving force. This prevents tire
scuffing when going around corners and premature
wear on internal axle parts. The ring and pinion
set and the differential are contained within an
aluminum carrier. You can find the axle identification
number on a tag attached to the right axle tube.
The drive axles (halfshafts) are completely flexible
assemblies consisting of inner and outer constant
velocity CV joints protected by thermoplastic boots and
connected by an axle shaft (output shaft).
Special Tools and Equipment
Illustration Tool Number/ Description

zR b — ■— -------------—— w
%
o
© <Z=3> J 8614
Pinion Flange Remover

1507

J 22761
Differential Side Bearing
Installer (K15-25)

5328

J 22833
Axle Seal Installer
(K35 Models)

156798

J 22888
Differential Side Bearing
Puller

162966
 : Illustration Tool Number/ Description

J 34011
Q U I]— , □ Differential Pilot Bearing
Remover

9099

9 156600
J 34672
Depth Gauge

J 35910
Drive Axle Seal Clamp
Pliers

5625

J 36366
Pinion Seal Installer

157993

J 36578
Holding Fixture and Pinion
Service Tool

156592
Illustration Tool Number/ Description

J 36597
Side Bearing Puller
Pilot (K35)

5322

J 36599
Side Bearing Adjuster
Wrench

156594

J 36600
Axle Tube Seal Installer
(K2 Models)

156805

J 36601
Pinion Depth Setting Gauge

156597

J 36603
Side Bearing Cup Installer

156605
Illustration Tool Number/ Description Illustration Tool Number/ D escription

J 29369-2
J 36616
Case Bushing Replacer Axle Tube Bearing and Seal
Remover (K35)

156810 57540

J 8107-2
J 36652
Side Bearing Puller Pilot
Clamp Swage Tool Set
(K15-25)

5725 5322

. Q y j- --------——
——---------
—-— -----
_ o
J 24319-B f) J 8614-01
Steering Linkage Puller Pinion Flange Holder

133 1507

J 29369-1
Axle Tube Bearing and Seal
Remover (K15-25)

57531
Rear Drive Axle
Specifications
Fastener Tightening Specifications (8 1/2 and 8 5/8)
Specification
Application Metric English
Brake Backing Plate 47 N-m 35 Ib ft
Carrier Cover 27 N-m 20 Ibft
Filler Plug 34 N-m 25 Ib ft
Pinion Shaft Lock Screw 34 N-m 25 Ib ft

Fastener Tightening Specifications (9 1/2 In Ring Gear)

Specification
Application Metric Inglish
Brake Backing Plate 142 N-m 105 Ibft
Carrier Cover 27 N-m 20 Ib ft
Filler Plug 24 N*m 18 Ibft
Pinion Shaft Lock Screw 34 N-m 25 Ibft

Fastener Tightening Specifications i10 1/2 In Ring Gear)

Specification
Application Metric English
Axle Flange Bolt 150 N-m 110 Ibft
Brake Backing Plate 150 N-m 110 Ibft
Carrier Cover 34 N-m 25 Ib ft
Filler Plug 35 N-m 26 Ib ft

Fastener Tightening Specifications (11 Inch Ring Gear)

Specification
Application Metric English
Axle Shaft Cap 21 N-m 15 Ibft
Bearing Cap Bolts 115 N-m 85 Ibft
Brake Backing Plate 105 N-m 78 Ibft
Carrier Cover 47 N-m 35 Ibft
Driving Pinion Nut 637 N-m 470 Ib ft
Filler Plug 33 N*m 24 Ibft
Outer Wheel Bearing Locknut 88 N-m 65 Ibft
Ring Gear Bolts 298 N-m 220 Ib ft

Spacer and Shim Specifications

Shim Type mm Irach
Differential Bearing Adjusting Shim 0.0726 0 003
Differential Bearing Adjusting Shim 0.1270 0 005
Differential Bearing Adjusting Shim 0.2540 0.010
Differential Bearing Adjusting Shim 0.7620 0.030
Outer Pinion Bearing Preload Shim 0.3556 0.014
Outer Pinion Bearing Preload Shim 0.3810 0.015
Outer Pinion Bearing Preload Shim 0.4064 0 016
Outer Pinion Bearing Preload Shim 0.4572 0 318
 Spacer and Shim S pecifications (cont’d)
Shim Type mm inch
Outer Pinion Bearing Preload Shim G5080 0 020

Outer Pinion Bearing Preload Shim 0.3534 0 02'i

Outer Pinion Bearing Preload Shim 0.5588 0 022
Outer Pinion Bearing Preload Shim 0.5842 0.023
Outer Pinion Bearing Preload Shim 0.7620 0.030
Inner Pinion Bearing Preload Shim 0.0762 0.003
Inner Pinion Bearing Preload Shim 0.1270 0.005
Inner Pinion Bearing Preload Shim 0.2540 0.010
Outboard Shim 5 18 0.204
Outboard Shim 5.26 0.207
Outboard Shim 5.33 0.210
Outboard Shim 5.41 0.213
Outboard Shim 5.49 0.216
Outboard Shim 5.56 0.219
Outboard Shim 5.64 0.222
Outboard Shim 5.72 0.225
Outboard Shim 5.79 0.228
Outboard Shim 5.87 0.231
Outboard Shim 5.94 0.234
Outboard Shim 6.02 0.237
Outboard Shim 6.10 0.240
Outboard Shim (Non-Selective) 4.98 0.196
Outboard Shim (Non-Selective) 4.88 0.192
Inboard Shim 0.84 0.330
Inboard Shim 0.69 0.270

Pinion Bearing and Differential Bearing Preload

Specification
Application Metric English
New Drive Pinion Bearings Preload 47 N-m 35 Ib ft
New Drive Pinion Bearings Final Tightening 57 N-m 42 Ib ft
Existing Differential Case Bearing Preload Tightening 57 N-m 42 Ibft
Existing Differential Case Bearing Final Tightening 68 N-m 50 Ib ft

Lubrication Specifications
Specification
Application Metric English
American Axle 8 V2 and 8 % Inch Ring Gear 2 .0 liters 2 .1 quarts
American Axle 91A> Inch Ring Gear 2 .6 liters 2.7 quarts
American Axle 1 0 1/2 Inch Ring Gear 3.08 liters 3.25 quarts
Dana 11 Inch Ring Gear 4.0 liters 4.2 quarts
C3500HD models in applications requiring extreme overload/trailer tow conditions at high speeds (above 45 MPH) for
extended periods of time should have lubricant changed every 3,000 miles or 3 months, whichever comes first. If synthetic
lubricant (GM P/N 12346140 or equivalent) is used, the change interval may be extended to 30,000 miles.
 GM SPO Group Numbers
Application GM SPO Group Number
Rear Axle 5.386
Rear Axle Bolt, Clip, Connector, Housing, Stud and Vent 5.387
Front and Rear Axle Bumper 5.395
Rear Axle Housing Bolt and Cover 5.398
Rear Axle Housing Cover Gasket 5.399
Rear Axle Shaft 5.420
Rear Axle Shaft Bolt, Cap, Gasket and Lock 5.422
Pinion Shaft Front Bearing, Cone and Cup 5.447
Differential Drive Pinion Front and Center Bearing Bolt and Spacer 5.453
Differential Pinion Cage Shim 5.458
Differential Rear Pinion Bearing Shim and Shim Kit 5.460
Differential Drive Pinion Seal 5.469
Pinion Bearing and Oil Seal Retainer 5.476
Drive Pinion Rear and Intermediate Baffle, Bearing, Cone and Cup 5.484
Final Drive Bracket, Shield and Washer 5.500
Differential Carrier 5.505
Differential Carrier Bolt, Bushing, Pin and Washer 5.506
Differential Carrier Housing Magnet 5.508
Differential and Planet Case, Cover and Differential 5.510
Differential Locking Bushing, Cam, Disc Set, Governor and Guide 5.511
Differential Locking Shaft 5.517
Pinion Shaft Lock Bolt and Pin 5,5': 8
Differential Pinion Spider 5.S2G
Differential Pinion Gear 5.523
Differential Side with Pinion Gear Kit 5 52?
Differential Side Gear b b<C
Ring and Pinion Gear Kit and Gear Set 5 529
Ring Gear Bolt 5.531
Differential Side Bearing . . . . . . | 5.536
Differential Bearing Adjusting Adjuster, Lock, Nut, Ring, Shim, Shim Kit, Sleeve and
5.537
Spacer
Differential Bearing Adjusting Nut Lock 5.539
Differential Pinion Thrust Block and Washer 5.542
Differential Side Gear Thrust Shim, Sleeve and Washer 5.543
Component Locator
Rear Axle Disassembled Views
Full-Floating Axle Wheel End Components

Legend

(1) Wheel Hub Bolt (12) O uter Bearing

(2) Caliper Mounting Plate Bolt (13) Wheel Bearing Spacer
(3) Dust Shield (14) Rear Wheel Hub
(4) Caliper Mount Bracket (15) Wheel Bearing Washer
(5) Washer (16) Adjuster Nut
(6) Nut (17) Lock Washer
(7) Wheel Bearing O il Deflector (18) Outer Locknut
(8) Oil Seal (19) Rear Axle Shaft Bolt
(9) Inner Bearing (20) Axle Shaft Cap
(10) Rear Brake Rotor (21) Axl e Shaft Gasket
(11) Retaining Ring (22) Rear Axle Shaft
 168041

Legend

(1) Pinion Nut (8) Preload Shims

(2) Washer (9) Axle Housing
(3) Pinion Flange/Yoke (10) Shims
(4) Pinion Oil Seal (11) Inner Pinion Bearing Cup
(5) Slinger (12) Inner Pinion Bearing Cone
(6) Outer Pinion Bearing Cone (13) Pinion
(7) Outer Pinion Bearing Cup
 168037

Legend

(1) Axle Housing (10) Shim

(2) Ring Gear (11) Bearing Cup
(3) Roll Pin (12) Bearing Cone
(4) Differential Case (13) Ring Gear Bolt
(5) Shim (14) Pinion Shaft
(6) Cover (15) Pinion Gear
(7) Cover Bolt (16) Pinion Thrust Washer
(8) Bearing Cap Bolts (17) Side Gear
(9) Bearing Cap (18) Side Gear Thrust Washer
Diagnostic Information and Procedures
Determining Type of Noise Tire Noise Test
Tire noise changes with different road surfaces, but
Rear Axle Noise rear axle noise does not. Temporarily inflating tires to
The proper diagnosis is an important part of rear axle 345 kPa (50 psi) pressure, for test purposes only,
repair. In axle work, one of the most difficult will materially alter noise caused by tires but will not
conditions to diagnose is noise. Locating a broken affect noise caused by the rear axle. Rear axle
axle shaft or broken differential gear presents little or noise usually stops when coasting at speeds under
no problem, but locating and isolating axle noise 30 mph; however, tire noise continues but with
can be an entirely different matter. lower tone as the vehicle speed is reduced. Rear axle
Any gear driven unit, especially an automotive drive noise usually changes when the tire pulls in a
axle where the engine torque multiplication occurs at a forward direction or when the vehicle coasts down the
90 degree turn in the driveline, produces a certain road and tire noise remains about the same.
amount of noise. Therefore, an interpretation must be Engine and Transmission Noises
made for each vehicle to determine where the
noise is normal or if a problem actually exists. A Sometimes a noise which seems to originate in the
certain amount of noise must be expected and cannot rear axle is actually caused by the engine or
be eliminated by conventional repairs or adjustment. transmission. To determine which unit is actually
causing the noise, observe approximate vehicle
Normal axle noise can be described as a slight speeds and conditions under which the noise is the
noise heard only at a certain speed or under unusual most pronounced; then stop the vehicle in a quiet
or remote conditions. For example, the noise tends place to avoid interfering noises. With the transmission
to reach a peak at speeds from 60 to 100 km/h in neutral, run the engine slowly up and down
(40 to 60 mph) depending on road and load conditions, through the engine speeds corresponding to the
or on gear ratio and tire size. This slight noise is in vehicle speed at which the noise was most
no way indicative of trouble in the axle assembly. pronounced. If a similar noise is produced with the
Driveline noises may confuse even the best technician. vehicle standing, it is caused by the engine or
Vehicle noises coming from tires, transmission, transmission and not the rear axle.
propeller shaft, universal joints, and front or rear wheel
bearings are often mistaken for axle noise. Such Front Wheel Bearing Noise
practices as raising tire pressure to eliminate tire noise Loose or rough front wheel bearings will cause noise
(although this will not silence tread noise of mud which may be confused with rear axle noise;
and snow tires), or listening for the noise at varying however, front wheel bearing noise does not change
speeds and road surfaces (drive, float, and coast when comparing pull and coast conditions. Light
conditions), will aid in locating the source of alleged application of the brake, while holding the vehicle
axle noises. Every effort should be made to isolate the speed steady, will often cause the wheel bearing noise
noise to a specific driveline component instead of a to diminish, since this takes some weight off the
making random guess that could be a costly bearing. Front wheel bearings may be easily checked
waste of time. for noise by jacking up the wheels and spinning
them, and also by shaking the wheels to determine if
External Noise the bearings are excessively loose.
Noise which seems to be coming from the rear axle
may actually be produced somewhere else. Determine Body Boom Noise or Vibration
whether the noise might originate in the tires, road Objectionable body boom noise or vibration at
surface, front wheel bearings, engine, or transmission. 55-65 mph (90-100 km/h) can be caused by an
unbalanced propeller shaft. Excessive looseness at
Road Noise the spline can contribute to this unbalance.
Driving on certain road surfaces, such as brick or Other items that may also contribute to the noise
rough-surfaced concrete, causes noise which may be problem are as follows:
mistaken for tire or rear axle noise. Driving on a
different type of road, such as smooth asphalt or dirt, • Undercoating or mud on the shaft, causing
will quickly show whether the road surface is the unbalance
cause of noise. Road noise usually is the same in drive • Shaft or companion flange balance weights
as in coast. missing
Tire Noise • Shaft damage, such as bends, dents, or nicks
Tire noise can easily be mistaken for rear axle noise, • Rough tires (Switch tires from a known good
even though noisy tires may be located on the vehicle in order to determine a tire fault.)
front wheels. Tires worn unevenly, or having surfaces If after making a comprehensive check of the vehicle,
on non-skid divisions worn in sawtooth fashion, are all indications point to the rear axle, further diagnostic
usually noisy and may produce vibrations which seem steps are necessary to determine the axle
to originate elsewhere in the vehicle. This is components at fault. True rear axle noise generally
particularly true with low tire pressure. falls into two categories: gear noise and bearing noise.
R ear A xle N o ise G ear N oise
If a careful test of the vehicle shows that the noise is There are two basic types of gear, noise.
not caused by external items, it is then reasonable
to assume that noise is caused by the rear axle
assembly. Test the rear axle on a smooth level road
to avoid road noise. It is not advisable to test the
rear axle for noise by running with the rear
wheels jacked up.
Noise in the rear axle assemb ly may be caused by a
faulty propeller shaft, faulty wheel bearings, fault
differential or pinion shaft bearings, misalignment
between two U-joints, or worn differential side gears
and pinions. Noise may be caused by a mismatched,
improperly adjusted, or scored ring and pinion
gear set.
Rear Wheel Bearing N oise
A rough rear wheel produces a vibration or growl
which continues with the vehicle coasting and
the transmission in neutral. A brinelled rear wheel
bearing causes a knock or click, approximately every
two revolutions of the rear wheel, since the bearing
rollers do not travel at the same speed as the rear axle 156406
and wheel. With the rear wheels jacked up, spin the
rear wheels by hand while listening at the hubs The first type is produced by broken, bent, or forcibly
for evidence of a rough or brinelled wheel bearing. damaged gear teeth (1) and is usually quite audible
over the entire speed range and presents no particular
D ifferential Side G ear and Pinion N oise problem in diagnosis. For example, hypoid gear
Differential side gears and pinions seldom cause noise tooth scoring generally results from the following-
since their movement is relatively slight on straight insufficient lubricant, improper break-in, incorrect
ahead driving. Noise produced by these gears will be ' lubricant, insufficient gear backlash, improper ring and
most pronounced on turns. pinion gear alignment, or loss of drive pinion nut
Pinion bearing failures can be determined by how the toque. The scoring will progressively lead to complete
bearings rotate at higher speeds as opposed to erosion of the gear tooth, or gear tooth pitting and
differential side bearings and axle shaft bearings. then eventual fracture if the initial scoring condition is
Rough or brinelled pinion bearings produce a not corrected.
continuous low-pitched whirring or scraping noise
Other causes of hypoid tooth fracture are extended
starting at a low speed.
overloading of the gear set which will produce fatigue
Side bearings produce a constant rough noise pitched fracture, or shock loading which will result in sudden
lower than pinion bearing noise. Side bearing noise
malfunction.
may also fluctuate in the previous rear wheel
bearing test.

156776
Differential pinion and side gears rarely give trouble. Abrasive Step Wear
Common causes of differential malfunction are
shock loading, and seizure of the differential pinions to
the cross shaft resulting from excessive wheel spin
and consequent lubrication breakdown (2). The second
type of gear noise pertains to the mesh pattern of
the gear teeth. This form of abnormal gear noise can
be recognized because it produces a cycling pitch
(whine) and will be very pronounced in the speed
range at which it occurs, appearing under either drive,
float or coast conditions. Drive is acceleration or
heavy pullout. Coast is allowing the vehicle to roll down
the road without accelerating and float is lightly
stepping on the accelerator pedal to keep the vehicle
from driving the engine; the vehicle slows down
gradually but the engine still pulls slightly. Gear noise
tends to peak in a narrow speed range or ranges
and will tend to remain constant in pitch. Bearing noise
will vary in pitch with vehicle speeds.
Refer to Rear Axle Wheel Bearing Wear for bearing
diagnoses.
1453

Rear Axle Wheel Bearing Wear The pattern on the roller ends is caused by fine
Tapered Roller Bearing Diagnosis abrasives.
Consider the following factors when diagnosing 1. Clean all of the parts and the housings.
bearing condition: 2. Check the seals and the bearings.
• General condition of all parts during disassembly 3. Replace any leaky, rough, or noisy bearings.
and inspection.
• Classify the failure with the aid of the illustrations. Galling
• Determine the cause.
• Make all repairs following recommended
procedures.
Abrasive Roller Wear

The metal smears on the roller ends are due to

overheating, lubricant failure, or lubricant overload.
1. Replace the bearing.
1452 2. Check the seals.
The pattern on the races and the rollers is caused by 3. Check for proper lubrication.
fine abrasives.
1. Clean all of the parts and the housings.
2. Check the seals and the bearings.
3. Replace any leaky, rough, or noisy bearings.
Etching

1455 1457

The bearing surfaces appear gray or grayish black in The wear around the outside diameter of the cage and
color, with related etching away of material usually the roller pockets is caused by abrasive material or
at roller spacing. inefficient lubrication.
1. Replace the bearings. 1. Clean the related parts and the housings.
2. Check the seals. 2. Check the seals.
3. Check for proper lubrication. 3. Replace the bearings.
Bent Cage . Indentations

1648

When a cage is damaged due to improper handling or The surface depressions on the race and the rollers
improper tool usage. are caused by hard particles of foreign matter.
Replace the bearing. 1. Clean all the parts and the housings.
2. Check the seals.
3. Replace rough or noisy bearings.
Frettage If this condition occurs, perform the following:
1. Replace the bearings.
2. Clean the related parts.
3. Check for proper fit and lubrication.
Stain Discoloration

The corrosion caused by small relative movement of

parts with no lubrication.
1. Replace the bearing.
2. Clean the related parts..
3. Check the seals. The discoloration on the bearings is caused by
4. Check for proper lubrication. . incorrect lubrication or moisture and ranges in color
from light brown to black. Reuse the bearing if you can
Smears remove the stains with light polishing and there is
no evidence of overheating. Check the seals and the
related parts for damage.
Heat Discoloration

The smearing of the metal is due to slippage. Slippage

can be caused by the following factors:
• Poor fits
The discoloration on the bearings ranges from faint
• Lubrication
yellow to dark blue and results from overload or
• Overheating an incorrect lubricant. Excessive heat causes softening
• Overloads of the races or the rollers. In order to check for loss
• Hand ling damage of temper on the races and the rollers, perform a
file test. A file drawn over a tempered part will grab
and cut the metal and fail the file test. A file drawn over
a hard part will glide readily with no metal cutting.
If overheating damage is indicated, perform the Fatigue Spalling
following:
1. Replace the bearings.
2. Check the seals and the other related parts.
Misalignment

The surface is flaked with metal due to bearing

fatigue.
1. Replace the bearing.
2. Clean all related parts.
1463
Brinelling
The outer race is misaligned due to a foreign object.
1. Clean the related parts.
2. Replace the bearing.
3. Ensure the races are properly sealed.
Cracked Inner Race

1466

The surface indentations in the race way are caused

by the rollers under impact loading or from vibration
while the bearing is not rotating. Replace a rough
or noisy bearing.

The race is cracked due to improper fit, cocking, or

poor bearing seats.
1. Replace the bearing.
2. Correct bearing seats.
Repair Instructions
Oil Seal and/or Bearing Replacement
Removal Procedure
Tools Required
• J 2619-01 Driver Handle.
• J 23690 Axle Shaft Bearing Installer.
• J 29709 Axle Shaft Bearing Installer
• J 21128 Axle Shaft and Pinion Seal Installer.
• J 29713 Axle Shaft Bearing Installer
(91/2 in ring gear)
1. Raise the vehicle on a hoist.
2. Remove the wheel and tire assembly.
3. Remove the brake drum (6).
4. Clean the dirt from the carrier cover (4) and
surrounding area.
5. Remove the carrier cover bolts (3) and clips.
6. Remove the carrier cover (4) from the housing (2).
• Catch the oil in a drain pan
• Remove any gasket material
7. Remove the screw.
 8. On axles without a locking differential, remove the
pinion shaft.

9. On axles with a locking differential, remove the

shaft part way, and rotate the case until the pinion
shaft touches the housing.

156411

10. On axles with a locking differential, use a

screwdriver or similar tool to enter the differential
case and rotate the lock (1) until it aligns with
the thrust block (2).

156412
 11. Push the flange of the axle shaft toward the
differential. Refer to Shaft Damage in General
Information.
12. Remove the lock from the button end of the
axle shaft.

156428

Important: Carefully slide the axle shaft (7) out in

order not to damage the seal (9).
13. Remove the axle shaft (7) from the housing (2).
14. Use the J 23689 to remove the seal (9).
15. Use the J 23689 for 8V2 and 8% inch ring gear
axles or the J 29712 for 91/2 inch ring gear axles
to pull the bearing (1) from the housing (2).

16. Insert the tool into the axle bore so that it grasps
behind the bearing.
17. Tighten the nut and washer against the face of
J 22813-01 the bearing.
18. Pull the bearing out using the J 2619-01.
19. Inspect all parts. Replace as necessary.
Installation Procedure
1. Lubricate the axle cavity between the seal lips
and the bearing with wheel bearing lubricant.
Refer to Lubrication Specifications in Maintenance
and Lubrication.
2. Install the bearing using the J 23690 for 8V2 and
8% in ring gear axles and the J 29709 for 91/2 in
ring gear axles.
3. Drive the bearing into the axle housing until the
tool bottoms against the tube.

156575

4. Install the seal using the J 2 1 128 for 8V2 and

8% in ring gear axles and the J 29713 for 91/2 in
ring gear axles.
5. Drive the tool into the bore until the seal bottoms
flush with the tube.

Important: Carefully insert the axle shaft (7) in order

not to damage the seal (9).
6. Install the axle shaft (7) into the housing (2).
7. Slide the axle shaft (7) into place allowing
the splines to engage the differential side gear.
8. On axles without a locking differential, place the
lock (8) on the button end of the axle shaft (7).

159446
 9. On axles with a locking differential, keep the
pinion shaft partially withdrawn.

10. On axles with a locking differential, place the

lock (1) on the axle shaft (3) so that the ends are
flush with the thrust block (2).
11. Pull the shaft flange outward in order to seat the
lock in the differential side gear.

Important: Anytime a differential pinion shaft locking

screw is removed, coat the screw threads with
Loctite 242 before reinstalling. The screw has an
adhesive coating in order to prevent the screw from
loosening in the case. Removing the screw removes
the adhesive on the screw.

12. Align the hole in the pinion shaft with the screw
hole in the differential case.

156410
13. Install the screw
Tighten
Tighten the screw to 3.4 N-m (25 Ib ft).
Notice: Refer to Fastener Notice in Caution and
Notices.

14. Install the carrier cover gasket or RTV (if used).

15. Install the carrier cover (4).
16. Install the carrier cover bolts (3) and clips.
Tighten
Tighten the bolts (3) in a crosswise pattern to
27 N-m (20 Ibft).
17. Install the brake drum (6).
18. Install the wheel and tire assembly.
19. Lower the vehicle.
20. Fill the housing with axle lubricant to the filler plug
hole level. Refer to Refer to Lubrication
Specifications in Maintenance and Lubrication.

159446

Pinion Oil Seal Replacement

(Semi-Floating Axle)
Removal Procedure
Tools Required
• J 5853-B Torque Wrench
• J 8614-01 Companion Flange Holder/Remover
• J 22388 Pinion Oil Seal Installer (91/2 in
ring gear axle)
• J 22836 Pinion Oil Seal Installer (8V2 and 8% in
ring gear axles)
• J 22804-1 Pinion Oil Seal Spacer
The pinion oil seal and the companion flange may be
replaced with the carrier assembly installed in the
vehicle.
 1. Raise the vehicle on a hoist and support the
vehicle with safety stands.
2. Remove the rear wheels and brake drums.
Im p o rta n t; Observe and accurately mark the positions
of all driveline components relative to the propeller
shaft and axles prior to disassembly. These
components include the propeller shaft, drive axles,
pinion flanges, output shafts, etc. Reassemble all
components in the exact relationship the components
had to each other during removal. Follow specifications
and torque values. Follow any measurements made
prior to disassembly.
3. Accurately marked the installed position of the
rear propeller shaft.
4. Remove the propeller shaft. Refer to Propeller
Shaft R eplacem ent - O ne-Piece or Propeller
Shaft Replacement - Two-Piece.
• Use a piece of tape in order to hold the
bearing caps
• Secure the propeller shaft so that the propeller
shaft is out of the way -
® Do not put unnecessary stress on the universal
joints in-securing the propeller shaft
5. Use a J 5853-B in order to measure the torque
required to turn the pinion.
6. Record the torque ■measurement,-which gives the
combined pinion bearing, seal, carrier bearing,
axle bearing and seal preload.
7. Make an accurate alignment mark (1) on the
pinion stem, pinion flange nut, and pinion
f lange (2).
8. Record the number of exposed threads on the
pinion stem.

156435
 9. Hold the pinion flange with the J 8 6 1 4 - 0 1 .
10. Remove the pinion flange nut and washer.
11. Use a container to catch any lubricant.
12. Remove the pinion flange using the J 8 6 1 4 - 0 1
with the remover attachment.
Important: Avoid damaging the machined surfaces.
13. Pry the oil seal from the bore.
14. Thoroughly clean any foreign material from the
contact area.
15. Repl ace any parts as necessary.

Installation Procedure
1. Install the oil seal into the bore using the
J 2 2 8 0 4 - 1 and either the J 2 2 3 8 8 (91/2 in ring gear
axles) or the J 2 2 8 3 6 (8V2 and 8% in
ring gear axles).
2. Turn the J 2 2 8 0 4 - 1 from the installed position
180 degrees to ensure proper installation
against the pinion flange.
3. Lubricate the cavity between the new seal lips
with a high melting point lubricant for bearings.

156579

Important: Do not hammer the pinion flange onto the

pinion stem.
4. Install the pinion flange using the J 8 6 1 4 - 0 1 .

156437
 5. Use the alignment marks (1) in the installation of
the pinion flange (2).
6. Install a washer and a new nut.
Tighten
Tighten the nut on the pinion stem as close as
possible to the alignment marks without going past
the mark.
Notice: Refer to Fastener Notice in Caution and
Notices.
• Use the record of the alignment marks and the
thread count as a reference.
• Tighten the nut a little at a time and turn the
pinion flange several times after each
tightening in order to set the rollers.

156435

Important: If the preload torque value recorded earlier

was less than 3 Ib in, reset the torque specification to
3-5 Ib in.
7. Measure the torque required to rotate the pinion
using the J 5853-B.
8. Compare the measurement of the torque with the
measurement made during the removal procedure.
9. Continue tightening and measuring a little at
a time until the preload is achieved.
10. Install the propeller shaft. Refer to Propeller Shaft
Replacement - One-Piece or Propeller Shaft
Replacement - Two-Piece.
11. Install the retainers and bolts.
Tighten
Tighten the bolts to 20 N-m (15 Ib ft).
12. Install the rear wheels and brake drums.
13. Lubricate the rear axle as necessary.
1497

Pinion Oil Seal Replacement

(10 1/2 Inch Ring Gear)
Removal Procedure
Tools Required
• J 8614-01 Companion Flange Holder/Remover
• J 24384 Pinion Oil Seal Installer
• J 5853-B Torque Wrench
The pinion oil seal and the companion flange may be
replaced with the carrier assembly installed in the
vehicle.
1. Raise the vehicle on a hoist and support with
safety stands.
Important: Observe and mark the positions of all
driveline components relative to the propeller shaft and
axles prior to disassembly. These components
include the propeller shafts, drive axles, pinion flanges,
output shafts, etc. All components must be
reassembled in the exact relationship to each as the
components had prior to disassembly. Follow all
specifications and torque values, as well as any
measurements made prior to disassembly.
2. Mark the installed position of the rear
propeller shaft.
3. Disconnect the propeller shaft. Refer to Propeller
Shaft Replacement (One-Piece) or Propeller Shaft
Replacement - Two-Piece.
• Use a piece to tape in order to hold the
bearing caps
• Secure the propeller shaft up and out of the
way in a manner that does not put
unnecessary stress on the universal joints
4. Measure the amount of torque required to turn the
pinion using the J 5853-B.
• Record the torque measurement for
reassembly
• The measurement give the combined pinion
bearing, seal, and carrier bearing preload.
5. Make an alignment mark (1) on the pinion stem,
pinion flange (2), and pinion flange nut.
6. Record the number of exposed threads on the
pinion stem for a reference.
 7. Hold the pinion flange with the J 8614-01.
8. Remove the pinion flange nut and washer.

9. Remove the pinion flange using the J 8614-01.

J 8 6 1 4 -3 10. Use a container to catch any lubricant.
Important: Do not damage the machined surfaces
11. Pry the oil seal from the bore.
12. Thoroughly clean foreign material from the
contact area
13. Replace parts as necessary.

1494

Installation Procedure
Tools Required
• J 8614-01 Companion Flange Holder/Remover
® J 24384 Pinion Oil Seal Installer
• J 5853-B Torque Wrench
Notice: Use the correct fastener in the correct
location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring
replacement or fasteners requiring the use of
thread locking compound or sealant are identified in
the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening
sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
 1. Lubricate the cavity between the lips of the new
seal with a high melting point lubricant.
2. Install the oil seal into the bore using the J 24384.
Important: Do not hammer the pinion flange (2)
onto the pinion stem.
3. Install the pinion flange using the alignment
marks (1) as a reference
4. Install the washer and a new pinion nut.
• Tighten the pinion nut on the pinion stem as
close to the alignment mark (1) as possible
without going past the mark
• Use the alignment mark and the thread count
as a reference
• Tighten the nut a little at a time and turn the
pinion flange (2) several times after each
tightening in order to set the rollers
Important: If the recorded preload torque value was
less than 3 Ib in, reset the torque specification to
3-5 Ib in.
5. Measure the torque required to rotate the pinion.
• Compare the rotating torque with the
recorded value
• Continue tightening the pinion nut and
measuring the torque until the recorded value
is achieved
6. Align the propeller shaft with the alignment marks.
7. Connect the propeller shaft. Refer to Propeller
Shaft Replacement (One-Piece) or Propeller
Shaft Replacement - Two-Piece.
8. Install the retainers and bolts.
Tighten
Tighten the bolts to 20 N-m (15 Ib ft).
Notice: Refer to Fastener Notice in Cautions and
Notices. 1497
9. Add lubricant to the rear axle as necessary. Refer
to Refer to Fluid and Lubricant Recommendations
in Maintenance and Lubrication.

Pinion Oil Seal Replacement

(11 Inch Ring Gear)
Removal Procedure
Tools Required
• J 8614-01 Pinion Flange Holder/Remover
• J 24384 Pinion Oil Seal Installer
The pinion oil seal and the pinion flange may be
replaced with the carrier assembly installed in
the vehicle.
1. Raise the vehicle.
2. Disconnect the propeller shaft. Refer to Propeller
Shaft Replacement - One-Piece or Propeller Shaft
Replacement - Two-Piece.
3. Make an alignment mark (1) on the pinion stem,
pinion nut and pinion flange (2) for use as an
installation guide.
 4. Remove the pinion nut using J 8614-01.

5. Remove the flange using J 8614-01 with the

special nut and forcing screw.
6. Pry the oil seal from the bore.
® Do not damage the machined surfaces
• Clean any foreign material from the
contact area
7. Inspect the following
• The oil seal mating surfaces for any burrs
which may cause seal failure
• Flange deflector for any abnormality such as
cracking or distortion
8. Replace parts as necessary.

1494

Installation Procedure
Tools Required
• J 8614-01 Pinion Flange Holder/Remover
• J 24384 Pinion Oil Seal Installer
1. Lubricate the inside diameter of the new oil seal
with extreme pressure lubricant such as GM
P/N 9985038.
2. Install the oil seal into the bore using the J 24384.
I mportant: Do not coat the bearing.
3. Pack the cavity between the pinion stem, pinion
flange and pinion nut with a non-hardening sealer
such as Permatex® Type A or the equivalent.

156490
 4. Install the pinion flange using the J 8614-01 and
use the alignment marks as a guide.
5. Install the pinion nut using the J 8614-01 and use
the alignment marks as a guide.
Tighten
Tighten the pinion nut to 596-678 N-m
(440-550 Ib ft).
Notice: Refer to Fastener Notice in Caution and
notices.
6. Install the propeller shaft. Refer to Propeller Shaft
Replacement - One-Piece or Propeller Shaft
Replacement - Two-Piece.

156437

Vent Hose Replacement

Removal Procedure
The axle vent hose is located on the axle carrier
on 81/2, 8%, and 91/2 in ring gear axles.

1. Remove the vent clamp bolt from the brake

bracket.
2. Remove the vent clamp from the brake bracket.
3. Remove the vent assembly from the vent hose.
4. Remove the vent clamp from the vent hose.
 5. Remove the vent damp bolt from the vent hose
clamp and brake junction block.

6. Remove the vent hose clamps and vent hose

from the axle nipples.
7. Remove the vent hose clamps from the vent hose.

Installation Procedure
1. Connect vent hose clamps to the vent hose.
2. Connect the vent hose clamps and the vent hose
to the axle nipples.

157129
 3. Install the vent hose clamp bolt to the vent hose
clamp and the brake junction block.

4. Connect the vent hose clamp to the vent hose.

5. Install the vent assembly to the vent hose.
6. Connect the vent hose clamp to the brake bracket.
7. Install the vent hose clamp bolt to the vent hose
clamp and the brake bracket.

Inspectio n Before Disassembly

1. Remove the cover and drain the oil.
Important: Use this information in the diagnosis of an
axle problem. Information on ring gear backlash
also helps in setting shim packs for locating and
preloading the differential case.
2. Check the ring gear backlash. Refer to Backlash
Adjustment.
Important: If possible, determine the cause the axle
problem before disassembly of the axle.
3. Inspect the case for metal chips and shavings.
Determine where the chips and shavings came
from, such as a broken gear or bearing cage.
 Drive Axle Disassemble
J 39704
Removal Procedure
Tools Required
• J 8107-2 Side Bearing Puller Plug
• J 8614-01 Pinion Flange Holder
• J 24385-01 Differential Housing Spreader
• J 29721 Differential Side Bearing Remover
• J 29721-70 Side Bearing Adapters
• J 39330 Bearing Race Remover
• J 39331 Outer Bearing Race Remover
• J 39704 Dial Indicator
• J 39709 Universal Handle
1. Place the axle in a suitable support.
2. Remove the bolts from the cover and the cover.
This will drain the oil.
168044 3. Pull the axle shafts out of the axle housing to the
point where the axle shafts are clear of the
differential case.
4. Remove the bearing cap bolts.
Important: Corresponding letters are stamped on the
bearing caps and axle housing. The bearing caps
must be reassembled exactly as removed.
5. Remove the bearing caps.
6 . Assemble the J 24385-01 to the differential
housing.
Notice: You may use the older style gage set if you
already have them. The new style gages use the
bearings as part of the gage system, while the older
style uses a master block that acts as a master
bearing.
7. Assemble the J 39704.
8. Preset the gage to a minimum of 5 mm (0.200 in).
Rotate the indicator housing to zero on the dial.
Notice: Do not spread the axle housing more
than 0.38 mm (0.015 inch). Overspreading the housing
may result in component damage.
9. Spread the housing while examining the J 39704.
10. Remove the case from the housing using two
pry bars.
11. Remove the J 24385-01 from the housing.
Important: Mark the bearing cups left and right and
place each bearing cup with the corresponding proper
bearing cap.
12. Remove the bearing caps.

168049

Important: Mark the bearings left and right and place

each bearings with the corresponding set of bearing
cap and cup. J 23721
13. Remove the bearings using the J 8107-2 J 29721
and J 29721-70
I mportant: Mark the shims left or right.
14. Remove the shims.
15. Check the outboard spacers for damage such as
bends or deep groves caused by worn bearings.
Replace any damaged spacers at the time of
assembly.
16. Place towels over the jaws of the vice. Place the
differential case in the vice
I mportant: Replace the ring gear bolts with new ones
at the time of assembly.
17. Remove the ring gear bolts. Discard the ring
gear bolts.
168046

N o t i c e : Do not pry the ring gear from the case. This

will damage the ring gear and differential case.
18. Remove the lock pin screw.
 19. Remove the pinion shaft using a hammer and
brass drift.

20. Rotate the side gears until the pinion gears are in
the opening of the case. Remove the pinion gears
and thrust washers.
Important: Mark the side gears and thrust washers
left and right
21. Remove the side gears and thrust washers.
22. Replace the cover using two bolts in order to keep
the pinion from falling.

168057

23. Measure the drive pinion rotating torque. Record

the measurement.
24. Check for looseness of the pinion assembly by
moving the assembly back and forth. Looseness
indicates excessive bearing or pinion wear.
25. Remove the pinion nut and washer using the
J 8614-01 in order to hold the pinion.

26. Remove the pinion flange using the J 8614-01.

27. Use a soft-faced hammer to tap the pinion in
order to remove the pinion from the pinion bore.
28. Remove the cover and the pinion from the vehicle
Important: Keep the shims together
29. Remove the pinion preload shims.
30. Remove the pinion seal.
31. Remove the outer bearing and oil slinger.
32. Remove the pinion outer bearing cups from the
axle using J 39330.
Important: Keep the shims together.
33. Remove the pinion outer adjusting shims and
baffle, if used.
34. Remove the pinion inner bearing cup using the
J 39331.
Important: Keep the shims together
35. Remove the pinion outer adjusting shims and
baffle, if used.
 36. Remove the pinion inner bearing using the
J 29721 and the J 29721-70.

168059
Axle Housing Inspection Important: Ring and pinion gears are matched sets
and both are replaced any time a replacement of either
Carefully and thoroughly inspect all drive unit parts
is necessary.
before assembly. Thorough inspection of the
drive parts for wear or stress with subsequent • Inspect the pinion and ring gear teeth for cracking,
replacement of worn parts el iminates costly drive chipping, scoring, and excessive wear.
component repair after assembly. • Inspect the pinion gear splines for wear.
• Inspect for nicks or burrs that could prevent the
• Inspect the pinion flange splines for wear.
outer diameter of the pinion seal from sealing.
Remove any burrs. • Inspect the fit of the pinion gear splines on the
• Inspect the bearing cup bores for nicks or burrs. pinion flange.
Remove any burrs that are found. • Inspect the sealing surface of the pinion flange for
• Inspect the housing for cracks. Replace the nicks, burrs, or rough tool marks that could cause
housing if any cracks are found. damage to the inside diameter of the seal and
• Inspect the housing for foreign material such as result in an oil leak.
metal chips, dirt, or rust. • Replace all worn or broken parts.

Differential Inspection Bearings Inspection

Carefully and thoroughly inspect all drive unit parts Carefully and thoroughly inspect all drive unit parts
before assembly. Thorough inspection of the
before assembly. Thorough inspection of the
drive parts for wear or stress with subsequent
drive parts for wear or stress with subsequent
replacement of worn parts eliminates costly drive
replacement of worn parts eliminates costly drive
component repair after assembly.
component repair after assembly.
• Inspect the pinion gear shaft for unusual wear.
• Inspect the pinion gear and side gear teeth Important: Bearings and cups are matched sets.
for wear, cracks, scoring, and spalling. Replace both bearing and cup when either part
requires replacement.
• Inspect the thrust washers for wear.
• Oil the bearings. Inspect the bearings for smooth
• Inspect the fit of the side gears in the
rotation.
differential case.
• Inspect the fit of the side gears on the axle shafts. • Inspect the bearing rollers for wear.
• Inspect the differential case for cracks and • Inspect the bearing cups for wear, cracks,
scoring. brinelling, and scoring.
• Inspect all parts for wear. Replace parts as
necessary. Shims Inspection
Carefully and thoroughly inspect all drive unit parts
Pinion and Ring Gear Inspection before assembly. Thorough inspection of the
Carefully and thoroughly inspect all drive unit parts drive parts for wear or stress with subsequent
before assembly. Thorough inspection of the replacement of worn parts eliminates costly drive
drive parts for wear or stress with subsequent component repair after assembly.
replacement of worn parts eliminates costly drive Inspect shims for cracks and chips. Replace damaged
component repair after assembly. shims with a service shim of an equal size.
 Pinion Depth Adjustment
Tools Required
• J 7818 Rear Pinion Bearing Cup Installer
• J 8092 Driver Handle
• J 39701 Master Discs
• J 39702 Arbor
• J 39704 Dial Indicator
• J 39707 Cup Installer
• J 39708 Handle
• J 41689 Pinion Height Block
• J 41690 Master Pinion Block
• J 41691 Adapter Cone
• J 41692 Threaded Rod
1. Clean the carrier bores and all tools. Make sure
the pinion bore is free of nicks and dirt.

168086 Important: Make sure the cup is seated.

2. Drive the inner bearing cup into the axle assembly
using the J 39708 and J 39707

Pinion Depth Adjustment

Distance
Between Ring
Gear Marking
And Pinion
Pinion Marking Head Shim Pack
Positive (+) Must Increase Decrease
Negative (-) Must Decrease Increase
Use Nominal
Zero (0) OK
Setting

3. Drive the outer bearing cup into the axle assembly

using the J 7818 and J 8092.
4. Install the inner bearing cone into the inner
bearing cup.

168079
N o t i c e : You may use the older styl e gage set if you
already have them. The new style gages use the
bearings as part of the gage system, while the older
style uses a master block that acts as a master
bearing.
Important: Install the outer bearing cone with the
J 41691.
5. Assemble the J 41690 and J 41689 into the
carrier housing using the J 41691 and J 41692.
6. Tighten the cone by hand until all end play is
removed from the gage assembly.
7. Assemble the J 3 9 7 0 2 and J 39701 into the
carrier housing.

8. Place the J 3 9 7 0 4 on the upper Step of the

J 41689.
• Apply pressure to the block of the J 3 9 7 0 4 ,
pushing down on the J 41689.
• While applying pressure, set the J 3 9 7 0 4
at zero.

9. Slide the J 3 9 7 0 4 over the J 3 9 7 0 2

10. Record the reading at the point of greatest J 39704
deflection, when the needle of the J 3 9 7 0 4 / / // J 39701
is centered between movement to the left
and right.
• This reading determines the amount of shims
needed for a nominal pinion setting.
• The pinion marking may change the pinion
depth by adding or deleting shims.
• Refer to the pinion marking table.

J 39701 J 39702

168401
11. After determining the pinion marking, remove the
J 39704, J 39702, J 41689, J 41692, J 41691, and
J 41690.
Important: If a baffle or oil slinger is used, measure
the baffle or oil slinger. Include this measurement
in the shim pack.
12. Measure with a micrometer each shim separately.
Add the dimensions in order to obtain the total
shim pack thickness.

Differential Case Assembly

Too l s Required
• J 24385-01 Differential Case Spreader
• J 39705 Master Differential Bearings
1. Lubricate all parts with an axle lubricant.
2. Install new thrust washers to the side gears.
Important: Install the side gears to the same side that
the side gears were on when removed.
3. Install the side gears to the differential case.
4. Install the pinion gears to the differential without
the thrust washers.
4.1. Install the pinion gears to the side gears so
that the holes in the pinion gears are
180 degrees apart.
4.2. Rotate the pinion gears into place. Verify
that the pinion gears line up with the pinion
shaft holes.
5. Rotate the pinion gears toward the differential
opening in order to allow enough space for the
pinion thrust washers to slide in.
6. Install the pinion shaft.
7. Align the roll pin holes in the differential case and
the pinion shaft.
8. Install the roll pin.
8.1. Peen metal from the case over the lock pin
in two places that are 180 degrees apart.
8.2. Make sure the mating surfaces of the
differential case and the ring gear are
clean and free of burrs.
9. Align the holes in the differential case and the
holes in the ring gear. Press the ring gear onto
the case.
Important: Tighten the ring gear bolt in stages in
order to gradually pull the ring gear onto the
differential case.
Notice: Refer to Fastener Notice in Cautions and
Notices.
10. Install new ring gear bolts.
11. Install the J 3 9 7 0 5 to the differential.
• Refer to Determining Total Shim P ack S ize in
this section.
• Put the outboard spacers in place, if outboard
spacers are used.

Determining Total Shim Pack Size

Tools Required
J 3 97 0 4 Dial Indicator
Notice: Both methods for setting differential bearing
preload and gear backlash are described. All Model 80
axle assemblies can be serviced by using the
outboard selective shim method.
Notice: If the original axle assembly has the outboard
selective shims, it should not be serviced using the
inboard shims for preload/backlash adjustment.
In other words, if you have outboard selective shims,
you must stay with that method. If the axle assembly
uses in board shims and outboard spacers
(non-selective), you may use the outboard selective
shim method for service.
Notice: If your axle assembly has selective outboard
spacers and one 0.76 mm (0.030 inch) shim
(each side) between the differential case and bearing
cone. Make your measurements with the outboard
spacers removed, but with the 0.76 mm (0.030 inch)
shim assembled on the differential case trunion placed
between the case and the master differential
bearings. The selective outboard spacers are available
in sizes (thickness) from 5.18 mm (0.2040 inch) to
6.10 mm (0.2400 inch), in 0.08 mm (0.003 inch)
increments. The dial indicator should have the
capability of making measurements up to
12.7 mm (0.500 inch).
Notice: If your axle assembly has outboard spacers,
but controls the preload and backlash by using
selective shims (each side) between the differential
case and bearing cone. Make the measurements with
the outboard spacers installed in the housing, but
do not place any shims on the differential case hubs
between the case and master differential bearings. The
selective shims placed between the bearing cone
and differential case are available in 0.08, 0.13, 0.25,
0.76 mm (0.003, 0.005, 0.010, 0.030 inch) sizes.
The dial indicator should have the capability of making
measurements up to 3.81 mm (0.150 inch).
 1. Assemble the case to the axle housing. The
pinion must not be installed.
2. Mount the J 39704 on the ring gear bolt side of
the differential housing.
3. Force the differential assembly as far as possible
in the direction of the J 39704.
4. Preload the J 39704 one half of its travel.
5. Place the tip of the J 39704 on a flat surface of
the differential next to a ring gear bolt.
6. Mark with chalk the location of the tip of the
J 39704.
7. Zero the dial indicator.
8. Force the differential case as far as possible in
the direction away from the J 39704. Repeat this
step until the same reading is obtained.
9. Record the number of thousandths that the dial
indicator traveled, not the reading on the dial.
This is the measurement of the shim pack without
the bearing preload, which will be added later.
10. Remove the J 39704.
11. Important
Do not remove the J 39704 from the differential.
Remove the differential from the housing.
Important: Removal of the spacers prevents the
spacers from falling out during the installation of the
pinion gear. Mark the spacers and indicate from which
side you removed the spacers. Reassemble the
spacers as removed in order to ensure that the shim
pack measurement is correct.
12. Remove any spacers used in the procedure from
the housing.

Pinion Installatio n
Tools Required
• J 5590 Rear Pinion Bearing Cone Installer
• J 8614-01 Pinion Flange Remover
• J 39707 Rear Pinion Bearing Cup Installer
• J 39708 Handle
• J 41696 Pinion Seal Installer
1. Place the required amount of shims in the inner
bearing bore. Include the baffle, if used.
2. Drive the inner bearing cup into the axle assembly
using the J 39708 and J 39707. Make sure the
cup is seated on the shims.
 3. Install the inner bearing cone on the pinion. Drive
the inner bearing cone onto the pinion shaft using
the J 5590.
4. Apply a light coat of axle lubricant to the lip of the
pinion seal.
5. Install the outer bearing cone, slinger, and oil seal
using the J 41689.
6. Install the preload shims onto the pinion gear.
7. Install the pinion into the axle housing.

N otice: Refer to Fastener Notice in Cautions and

Notices.
8. Install the washer and new pinion nut.
Tighten
Tighten the pinion nut to 637 N-m (470 Ib ft) while
holding the pinion with the J 8614-01.
9. Tighten the nut until the pinion end play is just
taken up. Rotate the pinion while tightening the
nut in order to seat the bearings.
10. Once there is no end play, check the preload
torque.
11. Remove the J 8614-01.

1496

Important: The pinion preload should be at or below

4 N-m (35 Ib in) on new bearings, or 1.2 N-m (10 Ib in)
on old bearings.
12. Check the pinion preload by rotating the pinion
with a torque wrench.
13. Once the specified preload has been obtained,
make sure the bearings are seated by rotating
the pinion several times.
14. Recheck the pinion preload. Adjust the pinion
preload as necessary.
 Differential to Axle H ousing Assem ble
• J 8001 Dial Indicator Set
• J 8092 Driver Handle
• J 23690 Differential Side Bearing Installer
• J 24385-01 Differential Housing Spreader
• J 39704 Master Differential Bearings
Notice: If your axle assembly has selective outboard
spacers and one 0.76 mm (0.030 inch) shim (each
side) between the differential case and bearing cone.
Make your measurements with the outboard spacers
removed, but with the 0.76 mm (0.030 inch) shim
assembled on the differential case trunion placed
between the case and the master differential bearings.
The selective outboard spacers are available in
sizes (thickness) from 5.18 mm (0.2040 inch) to
6.10 mm (0.2400 inch), in 0.08 mm (0.003 inch)
increments. The dial indicator should have the
capability of making measurements up to 12.7 mm
168076 (0.500 inch).
N otice: If your axle assembly has outboard spacers,
but controls the preload and backlash by using
selective shims (each side) between the differential
case and bearing cone. Make the measurements with
the outboard spacers installed in the housing, but
do not place any shims on the differential case hubs
between the case and master differential bearings. The
selective shims placed between the bearing cone
and differential case are available in 0.08, 0.13, 0.25,
0.76 mm (0.003, 0.005, 0.010, 0.030 inch) sizes.
The dial indicator should have the capability of making
measurements up to 3.81 mm (0.150 inch).
1. Force the ring gear to mesh with the pinion. Rock
the ring gear in order to allow the gear teeth
to mesh.
Im p o rta n t: The pinion must be installed
2. Assemble the differential with the master bearings
installed to the axle.
3. Mount a J 8001 with a magnetic base on the ring
gear bolt side of the housing.
4. Place the indicator tip of the J 8001 on the chalk
mark made earlier.
5. With force still applied to the differential case, set
the J 8001 to zero.
6. Force the differential case away from the pinion
gear in order to obtain a reading from the
J 8001.
7. Repeat the last step until a consistent reading is
obtained. Record the reading.
8. Remove the J 8001 and the differential case from
the axle housing.
9. Remove the J 39705 from the differential case.
10. Subtract the reading taken of the differential
movement from the total shim pack size
determined earlier. Refer to Determining Total
Shim Pack Size.
• Use the reading taken of the differential
movement for the shim size on the
ring gear side.
• Use the remainder from the equation in the
last step for the shim size on the side
opposite of the ring gear.
• Add an additional 0.25 mm (0.010) in) of shims
to the side opposite of the ring gear in order
to preload the bearings.
I m p o r ta n t: If the axle assembly uses the outboard
selective spacers, place the 0.76 mm (0.030 in) shim
on the hub that was used along with the master
bearings to make the measurement. Then select the
appropriate outboard selective spacer and assemble
the outboard selective spacer into the housing.
11. Place the proper shims on the differential side of
the bearing hub (ring gear side) and drive the
differential bearing onto the hub using the J 8092
and J 23690.
Important: If the axle assembly uses the outboard
selective spacers, place the 0.76 mm (0.030 in) shim
on the hub that was used along with the master
bearings to make the measurement. Then select the
appropriate outboard selective spacer and assemble
the outboard selective spacer into the housing.
12. Place the proper shims on the differential side of
the bearing hub (opposite of the ring gear) and
drive the differential bearing onto the hub
using J 8092 and J 23690.
13. Assemble the J 24385-01 to the axle housing.
14. Assemble the J 8001.
15. Preset the J 39704 to at least 0.05 mm (0.020 in).
16. Rotate the indicator housing in order to zero
the dial.
Notice: Do not spread the axle housing more
than 0.38 mm (0.015 inch). Overspreading the housing
may result in component damage.
17. Spread the housing while watching the J 8001.
18. Remove the J 8001.
19. Place the bearing cups onto the bearings.
20. Install the differential assembly into the carrier.
21. Seat the differential assembly into the axle using a
soft-faced hammer.

168093
22. R e m o v e th e J 2 4 3 8 5 - 0 1 .
Important: In stal l th e b e a rin g c a p s into th e e x a c t
p o sitio n s from w h ich e a c h h a d prior to rem o v al.
2 3 . Install th e b e a rin g c a p s .
Notice: R e fe r to F a s t e n e r N o t i c e in C a u tio n s a n d
N otices.
2 4 . Install th e b e a rin g c a p b olts.
Tighten
T ig h ten th e b e a rin g c a p b olts to i 15 N-m (85 Ib ft).

Backlash A djustm ent

Checking Backlash
1. M ount a J 3 9 7 0 4 with a m a g n e tic b a s e to th e a x le
h o u sin g .

Backlash Adjustment
Less G reater
Than 0.13 mm 0 .1 3 -0 .2 3 mm Than 0.23 m m
(0.005 in) (0.005-0.009 in) (0.009 in)
Move shims from Move shims from
the ring gear side
No change the side opposite
to the side
opposite of the of the ring to the
ring gear ring gear side.

2. P la c e th e in d icato r tip of th e J 3 9 7 0 4 o n th e h e e l
e n d (1) of th e ring g e a r to o th .
Important: T h e m e a s u r e m e n t m u s t n o t v ary m o re
th a n 0 .0 5 m m (0 .0 0 2 in) b e tw e e n th e p o in ts c h e c k e d .
3. C h e c k th e b a c k la s h a t th re e eq u a lly s p a c e d
po in ts.
Important: T h e re d u ctio n in th e sh im p a c k o n o n e
s id e m u s t b e e q u a l to th e in c re a s e in th e sh im p a c k o n
th e o th e r s id e .
4. If th e b a c k la s h n e e d s a d ju stm e n t, re m o v e th e
differential c a s e from th e h o u sin g .
5. If th e b a c k la s h is co rre c t, c h a n g e th e p re lo a d o n
e a c h s id e by a n e q u a l a m o u n t.
6. M ak e a final g e a r p a tte rn c h e c k . R e fe r to G e a r
T o o th C o n ta c t P a tte r n C h e c k .
Gear Tooth Contact Pattern Check
Before final assembly of the differential, perform a
gear tooth pattern check.
This contact patter check is not a substitute for
adjusting the pinion depth and backlash. Use this
method in order to verify the correct running position
of the ring gear and drive pinion. Gear sets which
are not positioned properly may be noisy, have a short
life, or both. A pattern check ensures the best
contact between the ring gear and the drive pinion for
low noise and long life.
Gear Tooth Nomenclature
The side of the ring gear tooth which curves outward,
or is convex, is the drive side (4). The concave
side is the coast side (3). The end of the tooth nearest
the center of the ring gear is the toe end (2). The
end of the tooth farthest away from the center is the
heel end (1).
7558

Testing Procedure
1. Wipe the oil out of the axle housing. Carefully
clean each tooth of the ring gear.
2. Use a medium stiff brush in order to sparingly
apply gear marking compound to all of the ring
gear teeth.
Important: A test made without loading the gears
does not give a satisfactory pattern.
3. Use the parking brake in order to apply a load
until a torque of 61 N-m (45 Ib ft) is required in
order to turn the pinion.
Important: Avoid excessive turning of the ring gear.
4. Turn the companion flange with a wrench so
that the ring gear rotates one full revolution.
5. Reverse the rotation so that the ring gear rotates
one revolution in the opposite direction.
6. Observe the pattern on the ring gear teeth.
Compare the pattern with the following
illustrations. Use the legend below:
6.1. (1) Toe
6.2. (2) Heel
6.3. (3) Coast side (Concave)
6.4. (4) Drive side (Convex)
 Condition
• T h e b a c k la s h is co rrec t.
• T h e pinion d e p th is inco rrect. T h e pinion g e a r is
to o fa r a w a y from th e ring g e a r.
Correction
In c re a s e th e th ic k n e s s of th e pinion sh im . R e fe r to
P in io n D e p th A d ju s tm e n t.
Service Hints
H ow to c h e c k th e p a tte rn :
1. B ru sh g e a r m ark in g c o m p o u n d o n th e ring
g e a r te e th .
2. R o ta te th e pinion c lo c k w ise six tim e s.
3. R o ta te th e pinion c o u n te rc lo c k w ise six tim e s.
4. O b s e r v e th e to o th c o n ta c t p a tte rn . M ak e
a n y n e c e s s a r y c o rre c tio n s.

7560

Condition
• T h e b a c k la s h is co rrec t.
• T h e pinion d e p th is co rrec t.
Correction
C o rre c tio n m a y n o t b e n e c e s s a r y .
Service Hints
L o o s e b e a rin g s o n th e pinion o r in th e differentia l c a s e
m a y c a u s e p a tte r n s th a t v a ry . C h e c k th e follow ing
p re lo a d s e ttin g s :
• T otal a s s e m b ly
• D ifferential c a s e
• P inio n
If t h e s e s e ttin g s a r e co rre c t, look for d a m a g e o r
in co rrectly a s s e m b le d p a rts.

7566

Condition
• T h e b a c k la s h is co rrec t.
• T h e pinion d e p th is in co rrect.
Correction
D e c r e a s e th e th ic k n e s s of th e pinion sh im . R e fe r to
P in io n D e p th A d ju s tm e n t.
Service Hints
T h e s h im s w hich a d ju st th e pinion d e p th a r e lo ca te d :
• B e tw e e n th e in n er pinion b e a rin g c o n e a n d th e
h e a r of th e pinion g e a r
• B e tw e e n th e in n er pinion b e a rin g c u p a n d th e re a r
a x l e h o u sin g
Adjustments'Affecting Tooth .Contact
There are two adjustments that affect the tooth contact
pattern: backlash and drive pinion depth. The effects
of bearing preloads are not readily apparent on
hand loaded tooth contact pattern tests. However,
bearing pre loads should be within specifications before
proceeding with backlash and drive pinion
adjustments.
Adjust the position of the drive pinion by increasing or
decreasing the distance between the pinion head
and the centerline of the ring. gear. Decreasing \
the distance moves the pinion closer to the centerline
of the ring gear. Increasing the d istance moves the
pinion farther away from the.centerline.of the ring gear.
Adjust the backlash by, means of the side bearing
adjusting shims which move the case and ring gear
assembly closer to, or farther from, the drive
pinion. Also use the adjusting shims to set the side
bearing preload.
If the thickness of the right shim is increased, along
with an equal decrease in the thickness of the
left shim, backlash will increase.
If the thickness of the left shim is increased, along
with an equal decrease in the thickness of the
right shim, the backlash will decrease..

Drive A xle Final Assem bly

1. Apply a thin layer of sealant to the axle cover.
N otice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the axle cover to the axle with the bolts.
T ig h te n
Tighten the axle cover bolts to 47 N-m (35 Ib ft).
3. Fill the axle with oil. Refer to Lubrication
Specifications.
4. Install the fill plug to the case.
 Axle Replacement (10 1/2 In Ring Gear)
Removal Procedure
1. Remove the bolts (6).
2. Lightly rap the axle shaft flange with a soft-faced
hammer in order to loosen the shaft.
3. Grip with a locking plier the rib on the axle shaft
flange and twist in order to start the axle shaft (5)
removal.
4. Remove the axle shaft (1) from the tube.
5. Clean the axle shaft flange.
6. Remove the gasket (4) and RTV.
7. Clean the outside face of the hub assembly (3).
8. Inspect all parts and replace as necessary.

160066

Installation Procedure
1. Install the axle shaft (5) with a gasket (4) or RTV
applied.
• Be sure the shaft splines mesh into the
differential side gear.
• Align the holes in the axle shaft flange with the
holes in the hub (3).
2. Install the bolts (6).
Tighten
Tight the bolts (6) to 150 N-m (110 Ib ft).
N otice: Refer to Fastener Notice in Cautions and
Notices.

Axle Replacement (11 Inch Ring Gear)

Removal Procedure
For Full-Floating Axle Wheel End Components refer to
Rear Axle Disassembled Views.
1. Remove the axle cap bolts.
2. Tap the axle cap lightly with a soft-faced hammer
to loosen the gasket.
3. Grip the rib on the axle shaft with a locking plier
and twist to start the axle shaft removal.
4. Remove the axle shaft from the tube.
5. Remove the old RTV or gasket.
6. Clean the hub assembly.
7. Inspect the shaft to see if it is bent.
8. Inspect the shaft spline for chips, burrs, cracking,
or excessive wear.
9. Replace any damaged components.
Installation Procedure
1. Install the axle shaft with RTV or the gasket,
being sure that the shaft splines mesh into the
differential side gear.
2. Install the axle cap and the bolts.
Tighten
Tighten the cap bolts to 20 N-m (15 Ib ft).
Notice: Refer to Fastener Notice in Cautions and
Notices.

Axle R eplacem ent (R ear Axle A ssem bly)

Removal Procedure
1. Raise the vehicle on a hoist.
2. Support the axle assembly with a suitable lifting
device.
3. Drain the lubricant from the axle housing.
4. Disconnect the propeller shaft. Refer to Propeller
Shaft Replacement - One-Piece or Propeller Shaft
Replacement - Two-Piece.
• Tie the propeller shaft to a side rail or
crossmember
• Tape the bearing cups to prevent loss of the
needle bearings
5. Remove the wheel and brake drum or hub and
drum assembly. Refer to Brake Lining
Replacement (Duo-Servo Drum Brakes) or Brake
Lining Replacement (Leading/Trailing Drum
Brakes) or Wheel Cylinder Replacement
(Leading/Trailing Drum Brakes) or Wheel Cylinder
Replacement (Components-Leading/Trailing) or
Wheel Cylinder Replacement
(Duo-Servo Drum Brakes )
6. Disconnect the parking brake cable from the lever
and at the brake backing plate. Refer to Park
Brake Cable Replacement (Front Cable) or Park
Brake Cable Replacement (Rear Cable - 1Ton)
or Park Brake Cable Replacement (Parking Brake
Cable) or Park Brake Cable Replacement (Rear
Cable - 1/2 and 3/4 Ton) in Parking Brake.
7. Disconnect the hydraulic brake pipes from the
connectors. Refer to Brake Pipe Replacement
in Hydraulic Brakes.
8. Disconnect the shock absorbers from the axle
brackets. Refer to Shock Absorber Replacement
(C Model) or Shock Absorber Replacement
(K Model) in Rear Suspension.
9. Remove the vent hose from the axle vent fitting.
Refer to Vent Hose Replacement.
10. Remove the nuts and washers from the U-bolts.
11. Remove the U-bolts, spring plates, and spacers
from the axle assembly.
12. Lower the axle assembly.
Installation Procedure
1. Place the axle assembly under the vehicle.
2. Align the axle assembly with the springs.
3. Connect the spacers, spring plates, and U-bolts to
the axle assembly.
4. Raise the axle assembly.
5. Install the washers and nuts to the U-bolts.
6. Instal l the vent hose to the axle vent fitting
(if used). Refer to Vent Hose Replacement
7. Connect the shock absorbers to the axle brackets.
Refer to Shock Absorber Replacement (C Model)
or Shock Absorber Replacement (K Model) in
Rear Suspension.
8. Connect the hydraulic brake pipes to the
connectors. Refer to Brake Pipe Replacement in
Hydraulic Brakes.
9. Connect the parking brake cable to the lever and
the brake backing plate. Refer to Park Brake
Cable Replacement (Front Cable) or Park Brake
Cable Replacement (Rear Cable - 1Ton) or
Park Brake Cable Replacement (Parking Brake
Cable) or Park Brake Cable Replacement
(Rear Cable - 1/2 and 3/4 T o n ) in Parking Brake.
10. Install the wheel and brake drum or hub and drum
assembly. Refer to Brake Lining Replacement
( D u o - S e r v o D r u m B r a k e s ) or B r a k e L i n i n g
Replacement (Leading/Trailing Drum Brakes) or
Wheel Cylinder Replacement (Leading/Trailing
Drum Brakes) or Wheel Cylinder Replacement
(Components-Leading/Trailing) or Wheel Cylinder
Replacement (Duo-Servo Drum Brakes ).
Important:
10.1. Check axle lubricant level at the filler
plug hole.
10.2. Lubricate as necessary. Refer to Refer to
Fluid and Lubricant Recommendations in
Maintenance and Lubrication.
10.3. Bleed the brake system, check brake
operation, and adjust if necessary. Refer
to H y d r a u l i c Brake S y s t e m Bleeding
in Hydraulic Brakes.
10.4. Check for fluid leaks.
10.5. Road test the vehicle.
11. Connect the propeller shaft. Refer to Propeller
Shaft Replacement - One-Piece or Propeller
Shaft Replacement - Two-Piece.
Axle Replacem ent (Assembly Installation Procedure
Replacement 11 Inch) 1. Place the axle assembly under the vehicle.
2. Align the axle assembly with the springs.
Removal Procedure 3. Connect the spacers, spring plates, and U-bolts to
1. Raise the vehicle and place jack stands under the the axle assembly.
frame side rails for support. 4. Raise the axle assembly.
2. Drain the lubricant from the axle housing. 5. Install the washers and nuts to the U-bolts.
• Firmly thread the nuts.
3. Disconnect the propeller shaft. Refer to Propeller
• Adjust the alignment of the axle assembly.
Shaft Replacement - One-Piece or Propeller Shaft
6. Connect the vent hose to the axle vent fitting.
Replacement - Two-Piece.
7. Connect the shock absorbers to the axle brackets.
4. Remove the tire and wheel assembly. 8. Connect the hydraulic brake lines to the
5. Remove the brake drum or hub and drum. connectors. Refer to Brake Pipe Replacement in
6. Disconnect the parking brake cable from the lever Hydraulic Brakes.
and at the brake flange plate. Refer to Park Brake 9. Connect the parking brake cable to the level and
Cable Replacement (Front Cable) or Park the flange plate. Refer to Park Brake Cable
Brake Cable Replacement (Rear Cable - 1Ton) or Replacement (Front Cable) or Park Brake Cable
Replacement (Rear Cable - 1Ton) or Park
Park Brake Cable Replacement (Parking Brake
Brake Cable Replacement (Parking Brake Cable)
Cable) or Park Brake Cable Replacement
or Park Brake Cable Replacement
(Rear.Cable - 1/2 and 3/4 Ton) in Parking Brake. (Rear Cable - 1/2 and 3/4 Ton) in Parking Brake.
7. Disconnect hydraulic brake pipes from the 10. Install the brake drum or hub and drum.
connectors. Refer to Brake Pipe Replacement in 11. Install the tire and wheel assembly.
Hydraulic Brakes. 12. Connect the propeller shaft. Refer to Propeller
8. Disconnect the shock absorbers from the axle Shaft Replacement - One-Piece or Propeller
brackets. Shaft Replacement - Two-Piece.
9. Disconnect the vent hose from the axle vent 13. Fill the axle assembly with axle lubricant to the
fitting. filler plug hole level. Refer to Lubrication
Specifications.
10. Support the axle assembly with a hydraulic 14. Bleed the brake system, check brake operation
floor jack. and adjust if necessary. Refer to Hydraulic Brake
11. Remove the nuts and washers from the U-bolts. System Bleeding in Hydraulic Brakes.
12. Remove the U-bolts, spring plates, and spacers 15. Remove the jack stands and lower the vehicle.
from the axle assembly. 16. Check axle operation.
17. Check for fluid leaks.
13. Lower the axle assembly.
18. Road test the vehicle.
Hub and Drum Assem bly Replacem ent
Removal Procedure
Tools Required
J 2222-C Wheel Bearing Nut Wrench
1. Raise the vehicle until the wheel is free to rotate.
2. Remove the wheel and tire.
3. Remove the axle shaft (5). Refer to Axle
Replacement (11 Inch Ring Gear).
4. Remove the retaining ring (10).
5. Remove the key (9).

6. Remove the adjusting nut using the J 2222-C.

7. Remove the washer.

8. Remove the hub and drum (3).

installation Procedure
1. Install the hub and drum (3) on the axle tube.
• Be sure the bearings and the oil seal are
positioned properly.
• Apply a light coat of high melting point
EP bearing lubricant to the contact surfaces
and the outside of the axle tube.
2. Install the washer.
3. Place the tang into the keyway.

4. Install the adjusting nut.

5. Adjust the bearing preload. Refer to Axle
Replacement (11 Inch Ring Gear)

156458

6. Install the key (9).

7. Install the retaining ring (10).
8. Install the axle shaft. Refer to Axle Replacement
(11 Inch Ring Gear).
9. Install the wheel and tire.
10. Lower the vehicle.
 Hub and R otor A ssem bly Replacem ent
Removal Procedure
For Full-Floating Axle Wheel End Components Refer
to R e a r A x le D is a s s e m b le d Views.
Tool Required
J 2 2 2 2 -C Wheel Bearing Nut Wrench
1. Raise the vehicle until the wheel is free to rotate.
2. Remove the tire and the wheel assembly.
3. Remove the axle shaft. Refer to Axle Replacement
(11 Inch Ring Gear).
4. Remove the nut using J 2 2 2 2 - C .
5. Remove the retaining ring.
6. Remove the lock or the key.
7. Remove the adjusting nut.
8. Remove the washer.
9. Remove the hub and the rotor.
156458
Inspect for any worn or damaged parts.
Replace any defective parts.
Installation Procedure
1. Connect the hub and rotor to the tube being sure
that the bearings and the oil seal are positioned
properly.
2. Apply a light coat of high melting point EP bearing
lubricant to the contact surfaces and on the
outside of the axle tube.
3. Install the washer and engage the tang in the
keyway.
4. Install the adjusting nut.
Tighten
• Tighten the adjusting nut to 68 N-m (50 Ib ft)
while turning the hub.
®sBack-off the locknut and re-tighten it to
41 to 54 N-m (30 to 40 Ib ft) while
rotating the hub.
• Back-off the nut 135 degrees to 150 degrees.
• The final bearing adjustment is
0.025 to 0.25 mm (0.001 to 0.010 inch).
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the lockwasher and the outer locknut.
6. Bend on of the ears of the lockwasher over the
inner nut to a minimum of 30 degrees.
7. Bend one of the ears of the lockwasher over the
outer nut to a minimum of 60 degrees.
Tighten
Tighten the nut to 88 N-m (65 Ib ft).
8. Install the axle shaft. Refer to A x le Replacement
(11 Inch Ring Gear).
9. Install the tire and the wheel assembly.
10. Lower the vehicle.
Bearing Cup R eplacem ent
(10 1/2 Inch Ring G ear)
Removal Procedure
Tools Required
• J 8092 Driver Handle
• J 8608 Pinion Bearing Cup Installer
• J 24426 Outer Bearing Cup Installer
• J 24427 Inner Wheel Bearing Cup Installer
• Axle Shaft Seal Installer
1. Raise the vehicle until the wheels are free to
rotate.
2. Remove the hub and drum. Refer to Hub and
Drum Assembly Replacement.
3. Remove the oil seal (2).
4. Use a drill to remove the inner bearing and the
cup (1).
5. Use snap ring pliers to remove the retaining
ring (11).
6. Remove the outer bearing ring using J 24426 and
J8092.

156462
 7. Drive the bearing and the cup (8) from the
hub (3).
8. Clean the old oil sealing compound from the oil
seal bore in the hub.
9. Clean the bearing assemblies in a solvent using a
stiff brush in order to remove the old lubricant.
• Dry the bearings with compressed air.
• Do not spin the bearings.
10. Clean the lubricant from the axle housing and
from inside the hub.
11. Remove the gasket material from the hub and the
axle shaft.
12. Inspect the bearings for wear, chipped edges or
other damage.
13. Check for flat or rough spots on the rollers.
14. Inspect the cups for pits and cracks.
15. Replace parts as necessary.

Installation Procedure
Tools Required
• J 8092 Driver Handle
• J 8608 Pinion Bearing Cup Installer
• J 24426 Outer Bearing Cup Installer
• J 24427 Inner Wheel Bearing Cup Installer
• Axle Shaft Seal Installer.
1. Install the outer bearing cup (8) into the hub (3).

160066

Important: Install the J 8608 upside down on the

J 8092 so that the chamfer does not contact the
bearing cup.
2. Drive the outer bearing cup into hub using the
J 8608 and the J 8092.

156462
 3. Drive the outer bearing cup (7) beyond the.
retaining ring groove.
4. Install the retaining ring (11) in the groove.
5. Drive the outer bearing cup onto the retaining
ring (11) using the : J -24426.
6. Install the. inner bearing cup using the J 2 4 4 2 7
and the J 8 0 9 2 .
7. Dri ve the inner bearing cup until it is seated
against the hub shoulder.
8. Instal l the inner bearing (1).
9. I nstal l a new oil seal (2) using the Axle Shaft Seal
Installer,.
10. Install the hub and drum assembly (3). Refer to
Hub and Drum Assembly Replacement
11. Install the wheel bearing adjusting nut (8).
12. Adjust the bearing preload. Refer to Wheel
Bearing Adjustment (10 1/2 Inch Ring Gear).
13. Install the axle shaft (5). Refer to Axle
Replacement (11 Inch Ring Gear).

B e a r i n g C u p R e p la c e m e n t
(11 I n c h R in g G e a r ) ■

Rem oval P ro ced u re ■ ■

Tools Required
• J 8092 Drive Handle
• J 8608 Outer Pinion Bearing Cup Installer
• J 24426 Outer Wheel Bearing Cup Installer
• J 24427 Inner Wheel Cup Bearing Installer
® J 39114-A Axle Shaft Seal Installer
1. Raise the vehicle until the wheels are free to
rotate.
2. Remove the axle shaft. Refer to Axle Replacement
(11 Inch Ring Gear).
3. Remove the hub and drum assembly. Refer to
Hub and Drum Assembly Replacement.
4. Remove the inner bearing and the oil seal.
• Lay the drum on a flat surface using a
shop towel in order to catch the bearing and
the seal.
• Use a drift to remove the bearing cup and
the seal.
5. Remove the retaining ring using snap ring pliers.
6. Remove the outer bearing using J 8092 with
J 24426.
7. Drive the bearing and the cup from the hub.
8. Clean the old sealing compound from the oil seal
bore in the hub.
9. Clean the bearing assemblies in a solvent using a
stiff brush to remove the old lubricant. Dry the
bearings with compressed air. Do not spin
the bearings.
10. Clean the lubricant from the axle tube and from
inside the hub.
 11. Clean the gasket material, if used, from the hub
and the axle shaft.
12. Inspect the bearings for any wear, chipped edges
or other damage.
13. Check for any flat or rough spots on the rollers.
14. Check the cups for any pits or cracks.
15. Replace and discard the old oil seal.
16. Pack the inner and the outer bearing with wheel
bearing lubricant GM P/N 1051344. Refer to
Lubrication Specifications.

Installation Procedure
Tools Required
• J 8092 Drive Handle
• J 8608 Outer Pinion Bearing Cup Installer
• J 24426 Outer Wheel Bearing Cup Installer
• J 24427 Inner Wheel Cup Bearing Installer
• J 39114-A Axle Shaft Seal Installer
1. Install the outer bearing cup into the hub using
J 8092 and J 8608. Drive the cup beyond the
retaining ring groove.
Important: Be sure to install J 8608 Upside down on
J 8092 so that the chamfer does not contact the
bearing cup.

33875
 2. Install the retaining ring into the groove. Drive the
cup back onto the retaining ring using J 24426.

3. Install the inner bearing cup using J 8092 and

J 24426. Drive the cup into place until it sits
against the hub shoulder.
4. Install the inner bearing.
5. Install the new oil seal using J 39114-A.
6. Install the outer bearing.
7. Install the hub and drum.

33870

W heel Bearing A djustm ent

(10 1/2 inch Ring Gear)
Removal Procedure
Tools Required
J 2222-C Wheel Bearing Nut Wrench
1. Make sure the brakes are fully released and do
not drag.
2. Pull or push the tire at the top back and forth in
order to check the wheel bearing play.
• Use a pry bar under the tire as an alternative.
• If the wheel bearing adjustment is correct,
movement of the brake drum in relation to the
brake backing plate will be barely noticeable.
• If the movement of the brake drum in relation
to the brake backing plate is excessive,
adjust the bearings.
 3. Raise the vehicle until the wheel is free to spin.
4. Remove the axle shaft. Refer to A x le Replacement
(10 1/2 In Ring Gear).
5. Clean the following from the keyway, the threads,
and the adjusting nut (8).
. 6. Remove the retaining ring (10).
7. Remove the key (9).
Notice: Refer to Fastener Notice in Cautions and
Notices.
8. Tighten the wheel bearing adjusting nut.
Tighten
Tighten the adjusting nut to 68 N-m (50 Ib ft) using
th e J 2222-C.
• Rotate the drum in the opposite direction as
the adjusting nut turns.
• Make sure the inner bearing roller assembly is
seated against the spindle shoulder.
9. Adjust the adjusting nut as follows:
9.1. Back off the adjusting nut one quarter turn.
9.2. Retighten the adjusting nut to
17 N-m (13 Ibft).
9.3. Align the closest adjusting nut slot with the
keyway in the axle spindle.

156468

Installation Procedure
1. Install the key (9) into the keyway and adjusting
nut slot.
2. Install the retaining ring (10).
3. Make sure the retaining ring is seated.
4. Install the axle shaft. Refer to Axle Replacement
(10 1/2 In Ring Gear).

160066
W heel Bearing A djustm ent
(11 Inch Ring G ear A xle)
Diagnostic Procedure
T o o ls R e q u ir e d
J 2222-C Wheel Bearing Nut Wrench
1. Make sure the brakes are fully released and do
not drag.
2. Pull or push the tire at the top back and forth in
order to check the wheel bearing play.
• Use a pry bar under the tire as an alternative.
• If the wheel bearing adjustment is correct,
movement of the brake drum in relation to the
brake backing plate will be barely noticeable.
• If the movement of the brake drum in relation
to the brake backing plate is excessive,
adjust the bearings.
Removal Procedure 156468
1. Raise the vehicle until the wheel spins freely.
2. Remove the axle shaft. Refer to Axle Replacement
(10 1/2 In Ring Gear).
3. Remove the retaining ring.
4. Remove the rear wheel bearing axle adjusting
nut key.
5. Adjust the adjusting nut.
T ig h te n
Tighten the adjusting nut to 68 N-m (50 Ib ft) with
the J 2222-C while rotating the hub assembly.
6. Make sure the bearing cones are seated and in
contact with the spindle shoulder.
7. Back off the adjusting nut and retighten the
adjusting nut while rotating the hub.
8. Back off the adjusting nut.
9. Retighten the adjusting nut while rotating the hub
assembly.
T ig h te n
Tighten the adjusting nut to 47 N-m (35 Ib ft).
10. Back off the adjusting nut 135-150 degrees.
Installation Procedure
1. Install the lock washer
2. Bend one tang of the retaining washer over a flat
of the adjusting nut to a minimum of 30 degrees.
3. Install the outer retaining nut.
T ig h te n
Tighten the outer retaining nut to a minimum of
88 N-m (65 Ib ft)
Notice: Refer to Fastener Notice in Caution and
Notices.
4. Make the final bearing adjustment 0.025-0.25 mm
(0.001-0.010 in).
5. Bend one tang of the retaining washer over a flat
of the outer nut to a minimum of 60 degrees.
6. Add wheel bearing grease in the bearings.
7. Install the axle shaft. Refer to Axle Replacement
(10 1/2 In Ring Gear).
D e s c r ip t io n a n d O p e r a t io n

Rear Axle Description Under light loads, the clutch plates alone tend to lock
axle shafts to the differential case, and therefore,
General Description locking each other. This is due primarily to the gear
These trucks use various rear axles. The axles can be separating load developed on the right clutch
identified by the ring gear size in inches, by pack. This induced clutch torque capacity resists
manufacturer (American Axle Manufacturing or Dana) motion between the side gear and the rear axle
and by the type of axle shaft used (semi-floating or differential case. The differential allows the wheels to
full-floating). American Axle Manufacturing axles turn at different speeds while the axle shafts
include the 8 V2, 8 %, 91/ 2, and 101/2 inch ring gear axle. continue to transmit the driving force. Also, heavier
Dana supplies an 11 inch ring gear axle. The locking throttle application will cause an axle speed differential,
differential is supplied by Eaton. but this starts the full-lock feature of the unit.
Full locking is accomplished through the'use of a
Rear Axle Operation heavyweight governor mechanism1, cam system, and
A basic differential has a set of four gears. Two are multi-disc clutch packs. The flyweights on the governor
side gears and two are pinion gears. Some differentials mechanism move outward to engage a latching
have more than two pinion gears. Each side gear is bracket whenever the wheel-to-wheel speed varies by
splined to an axle shaft; so each axle shaft turns when approximately 100 RPM or more. This action retards
its side gear rotates. a cam which, in turn, compresses the multi-disc clutch
packs locking both side gears to the case. The
The pinion gears are mounted on a differential pinion
100 RPM wheel-to-wheel speed allows for cornering
shaft, and the gears are free to rotate on this shaft.
without differential lockup.
The pinion shaft is fitted into a bore in the differential
case and is at right angles to the axle shafts. At vehicle speeds above approximately 32 km/h
(20 mph), the latching bracket overcomes a spring
Power is transmitted through the differential as follows: preload and swings away from the flyweights. At this
the drive pinion rotates the ring gear. The gear, vehicle speed or greater, the differential is designed
being bolted to the differential case, rotates the case. not to lock, since added traction is generally not
The differential pinion, as it rotates with the case, needed.
forces the pinion gears against the side gears. When
both wheels have equal traction, the pinion gears All axle parts of vehicles equipped with the locking
do not rotate on the pinion shaft because the input rear axle are interchangeable with those equipped with
force on the pinion gear is equally divided between the the conventional rear axle, except for the case
two side gears. Therefore, the pinion gears revolve assembly.
with the pinion shaft, but do not rotate around the shaft Dana Model 80 (11 Inch Ring Gear)
itself. The side gears, being splined to the axle
The Dana 11 inch ring gear axle uses a conventional
shafts and in mesh with the pinion gears, rotate the
ring and pinion gear set to transmit the driving
axle shafts.
force of the engine to the rear wheels. The gear set
If a vehicle were always driven in a straight line, the transfers the driving force at a 90 degree angle
ring and pinion gears would be sufficient. The from the propeller shaft to the axle shafts.
axle shaft could then be solidly attached to the ring
This axle is full-floating. The wheel hubs support the
gear and both driving wheels would turn at
axle shaft at the wheel ends. The shaft at the
equal speed.
wheel end is supported and splined to the hub
However, if it became necessary to turn a corner, the inner-diameter. The differential supports the other
tires would scuff and slide because the outside splined end of the shaft.
wheel would travel further than the inside wheel. To Two tapered roller bearings support the pinion gear. A
prevent tire scuffing and sliding, the differential allows shim pack between the inner pinion bearing cup
the axle shafts to rotate at different speeds. and the axle housing sets the pinion depth. A shim
When the vehicle turns a corner, the inner wheel turns pack at the front of the axle housing between the
slower than the out wheel and slows its rear axle bearing cone and pinion gear sets the pinion bearing
side gear (as the shaft is splined to the side gear), the preload.
rear axle pinion gears will roll around the slowed The ring gear bolts to the differential case.
rear axle side gear, driving the rear axle side gear and
wheel faster. Two tapered rolling bearings support the differential
case. Two methods are in use in order to control
Locking Rear Axle the differential bearing preload and drive gear to pinion
The locking rear differential allows for normal gear backlash.
differential function as indicated in the standard rear One method uses a 0.76 mm (0.030 inch) hardened
axle description. Additionally, the locking rear shim and a selective outboard spacer shim. The
differential uses multi-disc clutch packs and a speed location of the hardened shim is between each
sensitive engagement mechanism that locks both differential bearing cone and the differential case. The
wheels together if one wheel should spin excessively location of the selective outboard spacer shim is
during slow vehicle operation. between each differential bearing cup and the housing.
The other method uses selective shims between each Special Tools and Equipment
differential bearing cone and the differential case,
with outboard spacers between each differential
bearing cup and the housing.
When moving the ring gear with outboard selective
shims, choose shims of different thickness in order to
accommodate the change. For example: if a change
requires a shim on the ring gear side that is 0.13 mm
(0.005 inch) thinner, then the opposite side will
require a shim that is 0.13 mm (0.005 inch) thinner.
On axles built using the other method, accomplish gear
movement by moving shims from one side of the
differential case to the other. If the differential preload
needs to be changed, equal amounts must be
added or subtracted from each side.
Spread the axle housing in order to remove the
differential from the housing. When the spreader is
removed, the housing sets the bearing preload.
Two bearing caps hold the differential in the axle
housing. A pinion seal, hub seal, and RTV between the
cover and the housing seals the axle.

168032

A part number (2) and manufacturing date (1) on the

right axle tube, cover plate side, identifies all Dana
axles. The model number (3) is cast on the carrier.
Tags attached to the differential cover plate carry
information on limited slip lubrication (4) and the axle
ratio (5). The carrier does not have a drain plug.
 Illustration Tool Number/Description

^ -------------------------- 0
© J 8614-01
Companion Flange Holder

1507

J 21128
Axle Shaft and Pinion Seal
I nstaller

156502

J 22349

CfD Pinion Bearing Cup Installer

156498

J 22388
Pinion Oil Seal Installer
(91/2 in)

5327

J 22804-1
Pinion Oil Seal Spacer

9
156541
 Illustration Tool Number/Description

J 29709
Axle Shaft Bearing Installer

156531

J 29712
Axle Shaft Bearing Remover
(91/2 in)

156545

(( (ff) J 29713
Axle Shaft Bearing Installer
(91/2 in)

156537

J 39114-A

^99^ Axle Shaft Seal Installer

36472
Rear Drive Axle - Locking/Limited Slip Rear Axle
Specifications
Fastener Tightening Specifications
V erification
Application Metric [-inglic:-:;
7 5/S, 8 1/2, and 8 5/8" Differential Lockscrew 36 N-m 27 Ib ft
9 1/2" Differential Lockscrew 50 N-m 37 Ib ft

Thrust Block Sizes (Locking)

Color Code 7 5/8" 8 1/2" and 8 5/8" 9 1/2"
Purple 1.260" 1.322" 1.598"
White 1.264" 1.326" ■ 302"
Brown 1.268" 1.330" •; =606"
Yellow 1.272" 1.334" 1.S'-0"
Orange 1.276" 1.338" 1.6 ■4"
Pink 1.280"

CO
"j.
CM
j 3 l8"
Green 1.284" 1.346" -1 622"
Blue 1.288" 1.350" ■' 6?o"
Black — ' — 1,630"

Reaction Block, 10 1/2 Inch Axle

Gear Size Reaction Bloci'
10 1/2" 0.78?

Lubrication Specifications
Application Type of Material GM Part Number
GL-5 80W90 Lubricant —
Repair Instructions
Locking Differential D isassem ble
(10 1/2 C ase)
Removal Procedure
Tools Required
J 22912-01 Bearing Remover
1. Remove the ring gear and the differential side
bearings. Refer to Drive Axle Disassemble in
Rear Drive Axle.
2. Remove the case screws.
Set the unit on the right side case half.
3. Remove the case halves.
3.1. Pry the halves apart at the yoke hole
location.
3.2. Hold the side gear in the left side case half.
4. Remove the governor assembly.
5. Remove the latching bracket assembly.
206983
6. Remove the left side gear.
7. Remove the left side clutch plates and the
guide clips.
8. Remove the left side gear thrust washer.
9. Remove the following parts:
• The reaction blocks
• The pinion yoke
• The pinion gears
• The pinion thrust washers
10. Remove the right cam unit from the differential.
11. Remove the right side gear thrust washer.
Measure and record the overall length of the gear
assembly from the front of the gear to the back
of the thrust sleeve including the side gear thrust
washer.
12. Remove the thrust sleeve using the J 22912-01.
Press the sleeve from the side gear.
13. Remove the clutch plates.
14. Remove the guide clips.
15. Remove the wave washer.
16. Remove the cam plate.
17. Remove the side cam gear.
Cleaning and Inspection Procedure.
1. Clean all the parts with an approved solvent.
2. Inspect the following parts;
• The pinion gear and the side gear for wear,
cracks, scoring, and spalling
• The thrust washers for wear
• The fit of the side gears on the axle shafts
• The differential case for cracks and scoring
• The thrust sleeve for excessive wear
Do not replace the thrust sleeve unless
necessary.
• All the parts for excessive wear and breakage
3. Replace parts as necessary.
Important: If any damage to the differential case is
found, the differential must be replaced.
4. Inspect the side gear bore for scoring.
If scoring is present, replace the differential.
Cam Unit Assembly
1. Install a cam plate to the side cam gear.
2. Install a wave washer.
3. Install the clutch plates.
Alternate the plates and position the wave washer
as shown.
4. Install the thrust sleeve.
Press the thrust sleeve flush with the side gear
disc spline.
5. Install the guide clips to the plates.
5.1. Use a chassis grease in the clips in order
to hold the clips in place on the plates.
5.2. If the side gear or the thrust sleeve has
been replaced, measure and record the
overall length of the gear to the back of the
thrust sleeve including the side gear
thrust washer.
5.3. Compare the reading with the reading
obtained earlier.
5.4. If the new reading is more than 0.0762 mm
(0.003 in) higher or lower than the original,
select a side gear thrust washer that will
return the reading closest to the original
reading.
Adjustment of the Differential
1. If it is necessary to replace the cam gear, the
right hand side gear, or the reaction blocks, the
entire differential must be adjusted. The differential
is adjusted using selective thickness thrust
washers behind each side gear, and the selective
thickness thrust washers between the reaction
blocks.
2. Build up the differential properly.
The proper clearance between parts is critical to
the operation of the unit.
3. Note the three adjustments necessary as follow:
• The left side gear backlash
• The right side gear backlash
• The thrust block clearance
Right Side Gear Backlash Adjustment
1. Install the cam unit and the side gear thrust
washer to the right case half.
2. Clamp the cam unit in place using a set of
washers, nut, and a bolt long enough to hold the
cam unit in place.
3. Place the pinion gears and the pinion thrust
washers on the pinion yoke.
4. Install the yoke firmly to the differential case half.
5. Loosen the nut.
6. Index one pinion gear tooth to point downward,
perpendicular to the case half face.
Tighten the nut.

206998
 7. Mount a dial indicator on the case half face using
a magnetic base.
8. Place the stem of the dial indicator on the pinion
gear tooth.
9. Pull the pinion gear firmly into the seat.
• Rotate the gear back and forth while reading
the dial indicator.
• Record the reading.
• Do not unseat the pinion yoke.
This will make the backlash reading inaccurate.
10. Repeat steps 5 through 9 on the remaining two
pinions.
11. The backlash should be between 0.254 and
0.457 mm (0.010 and 0.018 in).
12. If the backlash is too high, use a thicker side gear
thrust washer.
13. If the backlash is too low, use a thinner side gear
thrust washer.

Left Side Gear Backlash Adjustment

1. Assemble the clutch plates.
Alternate the plates as shown.
2. Assemble the guide clips to the plates.
Use grease in the clips in order to hold them in
place on the plates.
3. Install the following parts to the differential:
• The side gear thrust washer
• The clutch plate assembly
• The left side gear

CP
&

206994
4. Install the clamp the side gear in place using a
set of washers, a nut, and a bolt long enough to
hold the side gear in place.
5. Place the pinion gears and the pinion thrust
washers on the pinion yoke.

6. Install the yoke firmly to the differential case half.

7. Loosen the nut and the index one pinion gear
tooth to point downward, perpendicular to the
case half face.
Tighten the nut.

206998

8. Mount a dial indicator on the case half face using

a magnetic base.
9. Place the stem of the dial indicator on the pinion
gear tooth.
10. Pull the pinion gear firmly into the seat.
• Rotate the gear back and forth while reading
the dial indicator.
• Record the reading.
• Do not unseat the pinion yoke. This will make
the backlash reading inaccurate.
11. Repeat steps 7 through 10 on the other two
pinions.
12. The backlash should be between 0.051 and
0.254 mm (0.002 and 0.010 in).
13. If the backlash is too high, use a thicker pinion
thrust washer.
14. If the backlash is too low, use at a thinner position
thrust washer.
 Reaction Block Clearance Adjustment
1. Install the left side gear thrust washer, the clutch
plates, and the side gear.
Bolt the parts into position. Refer to Left Side
Gear Backlash Adjustment in this section..
2. Install the right side gear thrust washer and cam
assembly.
Bolt the parts into position. Refer to Right Side
Gear Backlash Adjustment in this section.
3. Measure the distance from the side gear face to
the case half face.
3.1. The thickness of the straight edge must be
subtracted from the reading.
3.2. Add the measurement of both sides
together. This is the side gear spread.

206999

4. Measure the thickness of the original reaction

blocks and the reaction block thrust washers
together.
5. If the combined reaction block and the thrust
washer thickness is not 0.000 to 0.1524 mm
(0.000 to 0.006 in) less than the side gear spread,
adjust the clearance using the following
procedure:
• Select a new reaction block thrust washer of
the correct thickness in order to
obtain 0.000 to 0.1524 mm (0.000 to 0.006 in)
clearance.
• Reshim the left and/or the right clutch
disc pack.
Maintain the side gear backlash. Refer to Right
Side or Left Side Gear Backlash Adjustment
in this section.
• Some of the older locking differentials had
select fit reaction blocks without a between
206967
thrust washer. These models require replacing
the reaction blocks with the correct thickness
reaction block.
Assembly of the Differential
1. Install the right thrust washer,
2. Install the right cam unit. Refer to Cam Unit
Assembly in this section.
3. Install the following parts:
• The reaction blocks
• The reaction block thrust washer
• The pinion yoke
• The pinion gears
• The pinion thrust washers
4. Install the left thrust washer.
Assemble the plates as shown.
o>

206994

5. Install the left side gear.

6. Install the latching bracket assembly.
7. Install the governor assembly.
The straight end of the latching bracket spring
must be over and outside the governor
assembly shaft.
8. Install the case halves together.
Hold the side gear in the left side case half.
9. Install the case screws.
10. Install the ring gear and the differential side
bearings. Refer to Assembly of the Rear Axle in
10 1/2 Inch Ring Gear.

Locking Differential Disassem ble

(8 1/2 and 9 1/2 Case)
T o o ls R e q u ir e d
J 26252 Governor Remover
1. Remove the governor bushing using J 26252.
 2. Remove the E-clips that hold the latching bracket
on the shaft. Move the bracket down the shaft.
3. Remove the latching bracket bushing using the
J 26252.
4. Remove the latching bracket, the shaft, and the
spring from the case.
5. Remove the governor assembly from the case.
6. Remove the lock screw.
7. Remove the pinion shaft.
8. Remove the differential pinion gear and pinion
thrust washer.
Rotate one of the side gears and roll the gears
out of the case.
9. Remove the thrust block and the right side gear.
10. Remove the right clutch plates and the side
thrust washer.
11. Remove the left side gear, the cam plate, and the
clutch plates as an assembly (cam unit).
12. Remove the side gear thrust washer.

Locking Differential Cam Unit Disassem ble

(10 1/2 A ssem bly)
Tools Required
J 22912-01 Bearing Remover
1. Measure and record the overall length of the gear
assembly from the front of the gear to the back of
the side thrust sleeve, including the side gear
thrust washer.
2. Remove the guide clips.
3. Remove the side thrust sleeve using the
J 22912-01.
Press the sleeve from the side gear.
4. Remove the clutch plates.
5. Remove the wave washer.
6. Remove the cam plate.
7. Remove the side cam gear.
206983
Locking Differential Cam Unit Disassem ble
(7 5/8 and 8.6 Assembly)
Removal Procedure
1. Remove the retaining ring using snap ring pliers.
2. Remove the clutch plates and the guide clips.

6343

Installation Procedure
1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. Install the clutch plates (7 5/8 ring gear = 8 plates,
8.6 ring gear = 10 plates). Alternate the plates.
4. Install the retaining ring (18).
5. Install the guide clips (13) and (16) to the clutch
plates. Use grease in the clips in order to hold
the clips in place on the plates.

6343

Locking Differential C leaning and

Inspection
1. Clean all of the parts using an approved solvent.
2. Visually inspect all the parts for excessive
wear or breakage. Replace the parts if necessary.
3. Check the pinion gear and the side gear teeth for
any the following conditions:
® Wear
• Cracks
• Scoring
• Spalling
4. Check the thrust washer for wear.
5. Check the fit of the side gears on the axle shafts.
6. Check the differential case for cracks and
scoring.
 Im portant; Do not replace the thrust sleeve unless
this is necessary.
7. Check the thrust sleeve for excessive wear.
8. Check the side gear bore for scoring, if scoring is
present, replace the entire differential.
9. Replace the differential if you find any damage to
the case.

Locking Differential Cam Unit A ssem ble

1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. Install the clutch plates.
Alternate the plates as shown.
4. Install the thrust sleeve.
Press the thrust sleeve flush with the side gear
di sc splines.
5. Install the guide clips to the clutch plates.
6. Install the guide clips to the clutch plates.
6.1 . Use grease in the clips in order to hold the
clips in place on the plates.
CP
& 6.2. If the side cam gear or the side thrust
sleeve has been replaced, measure and
record the overall length of the gear
assembly from the front of the gear to the
back of the side thrust sleeve, including the
206994 side gear thrust washer.
6.3. Compare the reading with the reading
obtained earlier in this section.
6.4. If the new reading is more than 0.0762 mm
(0.003 in) higher or lower than the original,
select a thrust washer that will return
the reading closest to the original reading.

Locking Differential Adjustm ent

1. Assemble the clutch plates. Alternate the plates
as shown.
2. Assemble the guide clips and to the plates. Use
grease in order to hold the clips in place on the
plates.
3. Install the side gear thrust washer, the clutch
plate assembly and the right side gear to the
differential.
4. Place the pinion gears and the thrust washers into
the differential.
5. Align the gears and the washers with the pinion
shaft hole.
6. Press down on the side gear. Install the pinion
shaft and the lock screw. Use a thinner side
gear thrust washer if you can not press the side
gear down far enough to install the pinion shaft.
7. Rotate the pinion gear closest to the lock screw
so that one of the teeth is pointing downward
(perpendicular to the ring gear flange).
8. Insert a large tapered tool, such as a screwdriver,
firmly between the side gear and the pinion shaft.
 9. Mount and zero in a dial indicator to the ring gear
flange. Place the stem of the indicator on one of
the teeth of the pinion gear closest to the
lock screw.
10. Pull the pinion gear firmly into the gear’s seat.
Rotate the gear back and forth while reading
the dial indicator. Record the reading.
11. Repeat steps 7 through 9 for the opposite
pinion gear.
12. The backlash should be between 0.051-0.243 mm
(0.002-0.010 in).
13. Use a thicker side gear thrust washer if the
backlash is too high. Use a thinner washer if
the backlash is too low.

Locking Differential Assem ble

1. Install the left side gear thrust washer.
2. Install the cam unit. Refer to Locking Differential
Cam Unit Disassemble (7 5/8 and 8.6 Assembly).
3. Install the right side gear thrust washer.
4. Install the right clutch plates with the guide dips.
Assemble the unit as shown.
5. Install the right side gear.
6. Install the thrust block, the pinion thrust washer,
and the pinion gear.
6.1. Place the pinion gears into the differential
180 degrees apart.
6.2. Rotate the gears and the thrust block into
position.
6.3. The open side of the thrust block must face
the small window opening.
Important: Install a new lock screw, finger tight.
7. install the pinion shaft.
8. Tighten to specifications after installation in the
vehicle. Refer to Fastener Tightening
Specifications in Rear Drive Axle.
Important: The straight end of the latching bracket
spring must be over and outside the governor
assembly shaft.
9. Install the governor assembly and the latching
bracket bushing.
10. Install the governor bushing.
10.1. Use the bushing with a straight hole, not
tapered.
10.2. Press the bushing in far enough to give
0.1016-0.508 mm (0.004-0.020 in) shaft
end play.
11. Install the latching bracket bushing.
Press the bushing in far enough to eliminate all of
the end play.
Special Tools and Equipment
illustration Tool Number/ Description Illustration Tool Number/ Description

J 22912-01
J 34672
Rear Pinion Bearing Cone
Remover Depth Gauge

> /

162970 156600

......- = o - ^
J 26252
J 7872
Locking Differential © b
Governor Remover Mag Base and Indicator

5309 35463

J 26900-2
1-2" Micrometer

163031
T ra n s fe r C a s e

Specifications
Fastener Tightening Specifications
(M anual S hift Transfer Case)

Application N-m Lb Ft Lb In
Adapter to Transfer Case Bolts 45 33 ; _9
Adapter to Transmission Bolts 45 33 ' -*•
Drain and Fill Plugs 47 35
Propeller Shaft Yoke Nuts 149 110
Shift Control to Floor Panel Bracket Bolts 11 — 97
Transfer Case Shield Bolts 35 26 —
Transfer Case Shift Control Bezel Screws 2 — 18
Transfer Case Vent Hose Clip Nut 6 —- 53

Approximate Fluid Capacities

Application Liters Gallons Quarts
NV261 Transfer Case — Use Dexron® III Oil GM
2.2 — 2.3
P/N 12346143
Schematic and Routing Diagrams
Transfer Case Control Schematic References
Section Number Subsection
Reference on Schematic Nairn?
Fuse Block Details Cell 11 8 - Wiring Systems
Ground Distribution Cell 14 8 - Wiring Systems
Instrument Panel Cell 81 8 - instrument Panel, Gauges
and Console
Power Distribution CelMO 8 - Wiring Systems

Transfer Case Control Schematic Icons

Icon Icon Definition
Refer to Electrostatic Discharge (ESD) Sensitive Devices in Cautions and Notices

Ia n ,
19384

Refer to OBD II Symbol Description Notice in Cautions and Notices

4 O B D 11 V

19385
 Driveline/Axle
pjojlnRuii
" “ “ "MP
ILLUM Fuse
I 4WD
20 A
E3

D4( j Fuse 14
10 A
Block

0.35 GRY 8 Fuse Block

0.8 BRN 241
1 BRN 241
Fuse Block 521711- - - Details
S2351 Details Cell 11
Cell 11 0.5 GRY 8
F3 0.8 BRN 241 ■C120 ■
—«—
0
r -
"* Spare Power 0.8 GRY/BLK 1694 a
E, C298
0.8 BLK/ 1695
1Source WHT 0.5 GRY 8
I (Convenience ■0.5 GRY/BLK 1694 To Auxiliary
j Center) 1570 Heater And
&P101 >P101 S253
E5 A/C Controls
Cell 63
Diesel/Base
/ Suburban
Only
R96 Cab Diesel
Pickup Only B
Transfer Case
(Auto)
B3 C2
23
Transfer r " " “
D2 C1 (Diesel)
19 ^ C4(Gas)
- — i vehicle
©
aT
Mode Selector
Illumination Lamp
Case 1: * Control
Switch 1 1Module S259 t It
- -- ------------------ J (VCM) (Gas) 5 BLK 150
Powertrain AJ G202
4WD 5 BLK 150 * Cross

C120
0.8 BLK/WHT — «—
Control
Module ;
0.8 BLK/WHT (PCM) (Diesel)
S111
® Indicator
Lamp
i
Ground
Distribution
Cell 14
Body
Ground

S302 <k 1695 1695 bT

\ 1 BLK/ 1695'
0.8 BLK 150" “ WHT
C ; C120
C210
S162(Gas) l ‘ Convenience
S107(Diesel) l 1Center
Dt
i I

Transfer Case
(around
Distribution
1 BLK 150 Cell 14 0.8 BLK/ 1695
T WHT
S147^ —J D6, C100
3 BLK 150 0.5 BLK 150
1 BLK/ 1695
WHT
:G105

4-179
Engine Ground
 4-180
|Hot At All Times! lHot In Run And Start!
IP
"! Transfer

Transfer Case
| E7 I TCASE Hs T GAUGES ] Fuse
1
iI
^ . C Fuse 2
D8 V
rm .
^ Fuse 4
.17 ▼
I Block
i 4 - LO Select SW Case
f*V.___ Select
Switch

Fuse Block
0.8 PNK 39
S213 0.35 PNK
4 -H I Select SW

2 —HI
IND
4 -H I
IND
4 —LO
IND
a
Details 2 -H I Select SW LP LP
LP
Cell 11 39
pQ "
0.35 PNK 39
i 9 l 11 I ~ i ___
ioibk
... .. ^. jf«*» m
mmm
mmm
mmm
mm^ .. m
mmXi <■■»•■■■■ earn** L
1 ORN 1640 B G" F

S270
0.5
DKGRN/ 1562
Ai
0.5
DKGRN/ 1559 WHT
1 ORN 1640 1 ORN 1640 WHT
0.5 TAN/ 1566
0.5 GRY/ 1564 BLK
BLK
1 ORN 1640 0.5
LT GRN/ 1563 0.5 PPL/ 1565
BLK WHT
C6 . D14- . *D15> C8 C3 C5 C4 A C11J C12„ C14
B+ Motor Motor Ignition Button Button Button 2 HI 4 HI 4 lo ’'Transfer
Supply Supply 4 LO 4 HI 2 HI Lamp Lamp Lamp i
I Control
1Module
Motor Motor Case Power
Ground Ground Ground Ground Diagnostic
D12^ D13w D10 C10 “D3r

1 BLK 150
1 0.8 BLK 150
1 BLK 150 0.8 BLK 150
0.5 ORN 1568
S298 Ground
Distribution
Cell 14
Ground
------------------1h. Distribution
S204 Cell 14

Driveline/A xle
3 BLK 150
1 BLK 13.
150 Data Link
G200 Connector
IP Ground
 Driveline/Axle
r r *
1Vehicle Control "* Cruise Vehicle Passlock/EVO
1 1Module (VCM) 1Control 1 1Speed 1Module
1 j1 A 1 I
1Module 1Sensor
3
' K
G4 i i A ■* A
L, .
14 J Buffer
A8
16 C2
0.5 DK
GRN/WHT 817 Diesel
Only j Only
1 Park/Neutral
D4 i : C100 1Position 0
Gas 0.5 DK GRN/WHT * Switch
Only 817
0.5 DK 0.5 DK B Cl
■0.5 DK £ P1O0 0.8
GRN/WHT 817 GRN/WHT 817 GRN/WHT 817
LT r ■
Stop
r GRN 275 i
0.5 DK GRN/WHT •Lamp
817 S221 0.8 YEL 1737 i -1' 1Switch
L. < j
v D i 0200 0.8 LT GRN C
C100 v200 275
0.5
DK GRN/ 817 A 0.8 LT GRN 275
0.5 YEL 1737
WHT 0.8 BLK/ 1695
WHT
D8 Cl. D16 D2
Speed Front Park Park 1 Transfer
Sensor Axle Neutral Signal •Case
Motor Motor I Control
I Encoder Encoder Encoder Encoder Encoder +8VReference Control Control
L Ground Channel P Channel C Channel A Channel B Voltage A B I Module
D 4" J (TCCM)
C9 D5 ' D6 N D7 " 02” C16 D1
0.5 0.5
0.5 BRN/ 1555 DK BLU/ 1557 LT GRN/ ■431 1 BLK 1552 A -
WHT WHT BLK
■ 1554 0.5 RED/ 1556 0.5 YEL/ 1558 1 RED 1553
WHT WHT BLK
P100

Transfer Case
B, ~--------D> ---------------E,
■ C, / “ F -4
„ C224
A> C225
0.5 0.5
' 1554 LT GRN/ - IBLK 1552
WHT DK BLU/ 1557
0.5 BRN/ 1555 BLK
WHT
WHT 0.5 RED/ 1556 . 0.5 YEL/ 1558 1 RED 1553
WHT BLK
F, I C.J B, D*
AA B,
E- Transfer
Ground Channel P. Channel C Channel A Channel B - 3V Reference Transfer
Voltage Case Case Encoder
M Motor

4-181
Encoder

187317
4-182 Transfer Case D riveline/A xle
187320
 Driveline/Axle
VEHICLE CONTROL MODULE
CONNECTOR IDENTIFICATION
01 - BLU - 32 WAY
11P 1, r* 02 - RED - 32 WAY
Transfer Case 4WD C3 - CLR - 32 WAY
Ilium * Fuse Mode Selector Indicator C4 - BLK — 24 WAY
Illumination Lamp 0
Fuse14 I B lO C k Lamp C5 - BLK - 5 WAY
10A | 'A B DIESEL POWERTRAIN
j CONNECTOR IDENTIFICATION
0.5 BLK 150 S259 1 BLK 1150 Cl - BRN -32 WAY 0
C 2 -B R N - 24WAY
- ^ v C3- LTBLU •-32 WAY
1 BRN 0
5 BLK 150
i
Ground
0.5 GRY Distribution #6202
Cell 14 Cross Body
Auxiliary Ground
Heater And
A/CControls 0.8 BLK/WHT 1695
Cell 63
A j , C210 Transfer
ABS r —yr 1 Convenience Case
Center) FuseBlock Controls Synchronizer
0.8 BRN 241 , 1Center
Diesel Details
Only Ceil 11
► S326 0.8 BLK/WHT

0.8 BRN
241
0.8
LT
BLU 1296 0.8 BLK/WHT
0.8 1695
0.8 GRY/BLK C120
BRN 241 — —

1694
0.5 GRY/BLK 1694
P101S &P101
"C)2 Cl B3 C2 (Diesel)

Transfer Case
Diesel
Only 23 -----19vv C4 (Gas)
r 1 Vehicle Control
(Man) i I Module (VCM)
i 1 (GAS)
L - — . -* Powertrain Control
(Auto) Module (PCM)
Transfer (Diesel)
T L Case Auto
Switch Trans 150 Engine

4-183
Only
* G105 Ground
Component Locator
Transfer Case Control Components
Name Location Locator View Connector End View
Automatic Transfer Under LH side of IP, near Convenience T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Case Control Module Center C o m p o n e n t V iew s C o n n e c to r E n d V iew s

P o w e r a n d G ro u n d in g P o w e r a n d G ro u n d in g
Convenience Center Under LH of IP, on Bulkhead C o m p o n e n t Views in C o n n e c to r E n d V ie w s in
Wiring Systems Wiring Systems
C ru ise C o n tro l C ru is e C o n tro l C o n n e c to r
LR of Engine Compartment, near
Cruise Control Module C o m p o n e n t V ie w s in E n d V ie w s in Cruise
Bulkhead
Cruise Control Control
Selectable Four-Wheel T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Center floor console
Drive Indicator C o m p o n e n t V ie w s C o n n e c to r E n d V iew s

T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Front Axle Actuator RH rear side of the front drive axle
C o m p o n e n t V iew s C o n n e c to r E n d V ie w s

P o w e r a n d G ro u n d in g P o w e r a n d G ro u n d in g
IP Fuse Block LH of IP, near LF Door Jamb Switch C o m p o n e n t V ie w s in C o n n e c to r E n d V ie w s in
Wiring Systems Wiring Systems
In s tru m e n t C lu s te r In s tru m e n t C lu s te r
C o m p o n e n t V ie w s in in
C o n n e c to r E n d V ie w s
Instrument Cluster Upper LH of IP, near Steering Column
Instrument Panel, Instrument Panel,
Gauges, and Console Gauges, and Console
A u to m a tic T ra n s m is s io n
E le c tro n ic C o m p o n e n t
V ie w s (In te rn a l) in A T in te rn a l C o n n e c to r
Automatic E n d V ie w s in Automatic
Park/Neutral Position Transmissions-4L60-E or Transmissions-4L60-E or
At LH Center of Transmission
Switch A u to m a tic T ra n s m is s io n A T In te rn a l C o n n e c to r
E le c tro n ic C o m p o n e n t E n d V iew s in Automatic
V ie w s (In te rn a l) in Transmissions-4L80-E
Automatic
T ransmissions-4L80-E
E n g in e C o n tro ls P C M C o n n e c to r E n d
Powertrain Control Under RH end of IP, above Blower Motor,
in
C o m p o n e n t V ie w s V ie w s in PCM Connector
Module behind IP Compartment Box
Engine Controls (6.5L) End Views
E n te rta in m e n t E n te rta in m e n t C onnect:.
Radio Center of IP C o m p o n e n t V ie w s in E n d V ie w s in
Entertainment Entertainment
H y d ra u lic B ra k e s H y d ra u lic B ra k e s
Stoplamp Switch Top of Brake Pedal C o m p o n e n t V ie w s in C o n n e c to r E n d V ie w s in ;
Hydraulic Brakes Hydraulic Brakes
T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Transfer Case Control Under the l/P on the steering column
: C o m p o n e n t V ie w s C o n n e c to r E n d Views
Module (TCCM) support bracket
: (Selectable 4WD) (Selectable 4WD)
T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Transfer Case
RH side, center of the transfer case C o m p o n e n t V ie w s C o n n e c to r E n d V iew s
Encoder Motor
(Selectable 4WD) ' S electable 4 W D )

Transfer Case Mode T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l

Selector In the Switch C o m p o n e n t V ie w s C o n n e c to r E n d V iew s
Illumination Lamp (Selectable 4WD) (S e le c ta b le 4 W D )

T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
RH rear of the engine compartment, near
Transfer Case Relay C o m p o n e n t V iew s C o n n e c to r E n d V iew s
the center of the cowl
(Selectable 4WD) (S e le c ta b le 4 W D )

T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Transfer Case Select
On the l/P C o m p o n e n t V ie w s C o n n e c to r E n d V iew s
Switch
(S e le c ta b le 4 W D ) (S e le c ta b le 4 W D )

T ra n s fe r C a se C o n tro l T ra n s fe r C a se C o n tro l
Transfer Case
LH top of the transfer case C o m p o n e n t Views C o n n e c to r E n d V iew s
Switch (M30) (S e le c ta b le 4 W D )
(S e le c ta b le 4 W D )
 Transfer Case Control Com 3onents (cont’d)
Name Location Locator View Connector End View
Transfer Case Control Transfer Case Control
Transfer Case Component Views Connector End Views
Switch (MG5) LH top of the transfer case
(Selectable 4WD) (Selectable 4WD)
Transfer Case Control Transfer Case Control
Transfer Case Component Views Connector End Views
Switch (MT1) LH top of the transfer case
(Selectable 4WD) (Selectable 4WD)
Transfer Case Control Transfer Case Control
Transfer Case Connector End Views
LH top of the transfer case Component Views
Switch (MW3)
(Selectable 4WD) (Selectable 4WD)
Transfer Case Control Transfer Case Control
Transfer Case Component Views
Top of the transfer case Connector End Views
Synchronizer (Selectable 4WD) (Selectable 4WD)
Engine Controls VCM Connector End
Component Views in
Views in Engine
Engine Controls(4.3L), Controls(4.3L), VCM
Engine Controls
Connector End Views in
Component Views in
Vehicle Control Module Engine Compartment, near EBCM Engine
Engine Controls(5.0/5.7L), or
Controls(5.0/5.7L), or VCM Connector End
Engine Controls Views in Engine
Component Views in Controls(7.4L)
Engine Controls(7.4L)
Engine Controls Engine Controls
Vehicle Speed Sensor Connector End Views in
Under RH of IP Component Views in
Buffer Engine Controls(6.5L) Engine Controls(6.5L)
Inline Harness Connector
Engine Harness to IP Harness, LR of Harness Routing Views in End Views in Wiring
C100 Engine Compartment, at Bulkhead Wiring Systems Systems
Transfer Case Control
Harness Routing Views in Connector End Views
Cl 20 Rear of the engine, near the transmission Wiring Systems
(Selectable 4WD)
IP Harness, approx. 8 cm from Wiper Harness Routing Views in Harness Routing Views
C131 in Wiring Systems
Motor Breakout Wiring Systems
IP Harness, approx. 8 cm from Wiper Harness Routing Views in Harness Routing Views
C132 Wiring Systems in Wiring Systems
Motor Breakout
Behind RH of IP, near Heater Motor, in Harness Routing Views in Harness Routing Views
C200 Wiring Systems in Wiring Systems
foam wrap
Harness Routing Views in Harness Routing Views
C210 At Convenience Center in Wiring Systems
Wiring Systems
LH rear of the engine compartment, under Harness Routing Views in Harness Routing Views
C224 Wiring Systems in Wiring Systems
the brake master cylinder
LH rear of the engine compartment, under Harness Routing Views in Harness Routing Views
C225 the brake master cylinder Wiring Systems in Wiring Systems
Harness Routing Views in Harness Routing Views
C227 Near Stoplamp Switch in Wiring Systems
Wiring Systems
Harness Routing Views in Harness Routing Views
C228 Crossbody Harness to RF Seat in Wiring Systems
Wiring Systems
Harness Routing Views in Harness Routing Views
C298 RH Side of IP in Wiring Systems
Wiring Systems
Power and Grounding Power and Grounding
G103 RF of Engine, front of Intake Manifold Component Views in Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
G104 RF of Engine Component Views in Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
G105 (Diesel) RH top of the cylinder head Component Views in Connector End Views in
Wiring Systems Wiring Systems
 Transfer Case Control Components (cont’d)
Name Location Locator View Connector End View
P o w e r a n d G ro u n d in g P o w e r a n d G ro u n d in g
G200 Behind LH of IP, below Fuse Block C o m p o n e n t V iew s in C o n n e c to r E n d V ie w s in
Wiring Systems Wiring Systems
P o w e r a n d G ro u n d in g P o w e r a n d G ro u n d in g
RH of IP, mounted to HVAC Plenum
G202 C o m p o n e n t V ie w s in C o n n e c to r E n d V ie w s in
Bracket Wiring Systems Wiring Systems
LH rear of the engine compartment, at the H a rn e s s R o u tin g V ie w s in H a rn e s s R o u tin g V ie w s
P100 bulkhead in Wiring Systems
Wiring Systems
Engine Harness, Approx. 13 cm from EGR
S103 Valve Breakout, toward Taillamp Harness — —
Breakout
Engine Harness, Approx. 10 cm from
S111 EBCM Breakout — ■ . — .
Engine Harness, Approx. 18 cm from
S107 EBCM Breakout, toward EGR Valve — —
Breakout
Engine Harness, Approx. 8 cm from EGR
S147
Valve Breakout — —■
IP Harness, approx. 10 cm from Steering — —
S204
Column Harness Breakout
IP Harness, approx. 4 cm from Steering —
S213 Column Harness Breakout ■ —
IP Harness, approx. 8 cm from Instrument
S215 Cluster Breakout, toward Radio — —
Connectors Breakout
IP Harness, approx. 40 cm from
S221 — —
Instrument Cluster Breakout
IP Harness, approx. 8 cm from Steering
S235 Column Harness Breakout — —
IP Harness, approx. 10 cm from Steering —
S236 Column Harness, near P100 —
IP Harness, approx. 24 cm from
S298 Instrument Cluster Breakout, toward Radio — —
Breakout
Selectable 4WD Harness, approx. 10 cm
S302 from Transfer Case Relay Breakout, — —
toward Front Axle Switch
Transfer Case Control C o m ponent View s
(S electable 4W D)

Legend
(1) Convenience Center (3) Transfer Case Shift Illumination Lamp
(2) Selectable Four-Wheel Drive Indicator Lamp
 Transfer Case Switch (MT1) and Synchronizer

Legend
(1) Engine Harness (5) Transfer Case Switch
(2) Heated Oxygen Sensor Connectors (6) Transmission Connector
(3) Vehicle Speed Sensor (7) Park/Neutral Position Switch
(4) Transfer Case Synchronizer (8) Transmission Input Speed Sensor
 Transfer Case Switch (MW3) and C120

Legend
(1) Connector C120 (6) Transfer Case
(2) Heated Oxygen Sensor (7) Transfer Case Switch (1 ton)
(3) Vehicle Speed Sensor (8) Engine Harness
(4) Transfer Case Synchronizer (9) Heated Oxygen Sensor Connector
(5) Transfer Case Switch (V2 ton and % ton)
 Transfer Case Switch (MG5)

Legend
(1) Heated Oxygen Sensor Connectors (4) Transfer Case
(2) Vehicle Speed Sensor (5) Back-Up Lamp Switch
(3) Transfer Case Switch (6) Heated Oxygen Sensor Connector
 4
183946

Legend
(1) Heated Oxygen Sensor Connectors (3) Transfer Case Switch
(2) Vehicle Speed Sensor (4) Transfer Case
 Transfer Case Select Switch

183948

Legend
(1) Radio Connector (4) Rear Fan Switch
(2) Rear Wiper Switch (5) Electric Shift Transfer Case Switch or Fog
(3) Cargo Lamp Switch Lamp Switch
 Transfer Case Relay

Legend
(1) Transfer Case Relay
(2) Front Axle Actuator
 6.5L Diesel Engine, RH Side

172401

L egend
(1) Engine Harness (4) Grounds G150 And G105
(2) Generator Connector (5) Ground G104
(3) Turbo
 C224 and C225

Legend
(1) Cruise Control Module (7) Rear Lamp Harness
(2) Pass Through Grommet P100 (8) Engine Harness
(3) Connector C100 (9) Windshield Wiper Motor
(4) Connector C110 (10) Connector C225
(5) Connector C104 (11) Connector C224
(6) Connector C111
 P100

Legend
(1) Connector C102 (6) Connector C101
(2) LH Front Headlamp Connectors (Composite) (7) Ground G113
(3) Park And Turn Lamp LH Front (8) Connector C100
(4) LH Fog Lamp Connector (9) Pass Through Grommet P100
(5) Horn
Transfer C ase Control C om ponent Views
(A utom atic 4W D )
Automatic 4WD Support Wiring

Legend
(1) Automatic Transfer Case Control Module (4) Convenience Center
(2) IP Harness (5) IP Reinforcement Brace
(3) Daytime Running Lights Control (DRL)
Module
 4WD Support Wiring

429328

Legend
(1) Engine Harness (6) Transfer Case Switch (1/2 Ton, 3/4 Ton)
(2) Inline Connector: C120 (7) Transfer Case
(3) Right Bank Heated Oxygen Sensor (8) Transfer Case Switch
Connector (9) Left Bank Heated Oxygen Sensor Connector
(4) Vehicle Speed Sensor
(5) Transfer Case Syncronizer
Transfer Case Control Connector End Views Transfer Case Control Connector End Views
(Selectable 4WD) (Selectable 4WD) (cont’d)

fe w i— r 9 9 9 r c r r Cie )— r 7= rc r

.O .. . ...... - n a - o .
, D16 D16 M U W ,

183881 183881

• 12045470 • 12045470
Connector Part Connector Part
Information * 32-Way F Micro-Pack Information • 32-Way F Micro-Pack
100 Series Natural 100 Series Natural
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
C1 BLK/WHT 1695 Front Axle Switch Park/Neutral Position
02 LT GRN 275
LT Switch Output— Park
C2 431 5V Reference Voltage
GRN/BLK Transfer Case Control
DK GRN/ Transfer Case Select D3 ORN 1568 Module Diagnostics
C3 1559 Enable
WHT Switch Output—4 Low
Transfer Case Select D4 BRN/WHT 1555 Encoder Channel P
C4 WHT 1562
Switch Output—2 High D5 RED/WHT 1556 Encoder Channel C
Transfer Case Select DK BLU/
C5 GRY/BLK 1564 D6 1557 Encoder Channel A
Switch Output— 4 High WHT
C6 ORN 1640 Battery Fused Feed D7 YEL/BLK 1558 Encoder Channel B
C7 — — Not Used
DKGRN/
C8 PNK D8 817 Vehicle Speed Signal
39 Ignition Fused Feed WHT
C9 BLK/WHT 1554 Encoder Ground D9 —■ — Not Used
C10 BLK 150 Ground D10 BLK 150 Ground
Indicator Lamp Output— D11 .. — — Not Used
C11 PNK 1563
2 High
D12 BLK 150 Ground
Indicator Lamp Output—
C12 TAN/BLK 1566 D13 BLK 150 Ground
4 High
013 — Not Used
D14 ORN 1640 Battery Fused Feed
—
Indicator Lamp Output— D15 ORN 1640 Battery Fused Feed
C14 PPL/WHT 1565
4 Low Park/Neutral Position
D16 YEL 1737 Switch Output—
C15 — — Not Used
Park/Neutral
Transfer Case Motor
C16 BLK 1552
Feed CW

D1 Transfer Case Motor

RED 1553
Feed CCW
 Transfer Case Select Switch Transfer Case Relay

—L — 'I

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/' 9

^ ^
HaS rlcLi r1^1!
F
183888

• 12064769 Connector Part 12110539

Connector Part Information
Information • 10-Way F Metri-Pack M/P 280 FLXLK
150 Series Natural Circuit
Circuit Pin Wire Color No. Function
Pin Wire Color No. Function Four Wheel Drive Relay
30 LT/BLU 1296
A PNK 39 Ignition Fused Feed Feed-Coil
Four Wheel Drive
Transfer Case Select
B WHT 900 85 RED 1297 Synchronizing Relay
Switch Output—2 High
Feed-Coil
Transfer Case Select Front Axle Actuator
C GRY/BLK 1564 86 GRY/BLK 1570
Switch Output—4 High Output
DK GRN/ Transfer Case Select Four Wheel Drive Front
D 1559
WHT Switch Output—4 Low 87 BLK/WHT 1695 Wheel Lock
Indicator Lamp Output— Telltale Feed
E PPL/WHT 1565
4 Low 87A BLK 150 Ground
Indicator Lamp Output—
F TAN/BLK 1566 4 High
Indicator Lamp Output—
G PNK 901 2 High
H BLK 150 Ground
Instrument Panel
J GRY 8 Lamp Feed
K — ___
Not Used
Transfer Case Control Connector End
Views (Automatic 4WD)
Automatic Transfer Case Control Module

Connector Part • 12052107

Information * ASM 32M (BLK)
Circuit
Wire Color
Pin No. Function
4 ’LO’ Indicator Lamp
F1 PPL/WHT 1565
Connector Part 12052107 Output
information ASM 32M (BLK)
4 ’HP Indicator Lamp
F2 TAN/BLK 1566
Output _______
Circuit
Pin
Wire Color
No* Function
Neutral Indicator Lamp
F3 BRN 1560
Output______________
Transfer Case Lock
E1 TAN 1569
Solenoid Output F4 GRY/BLK 1570 Front Axle Actuator Output
Service 4WD/AWD F5 LT BLU 2221 VSS Signal
E2 LT BLU/BLK 1567 F6 DKGRN 2222 VSS Return
Indicator Lamp Output
AWD Indicator Lamp F7 GRY/BLK 1694 4WD Switch Signal - Low
E3 PNK 1561
Output F8 Not Used
2 ’HI’ Indicator Lamp F9 Not Used
E4 LT GRN/BLK 1563
Output F10 Not Used
Transfer Case Position F11 Not Used
E5 BRN/WHT 1555 Switch Encoder Signal - Transfer Case Encoder
Channel P F12 BLK/WHT 1554
Signal Return
Transfer Case Position Reference Voltage Feed
E6 RED/WHT 1556 Switch Encoder Signal ■ F13 LT GRN/BLK 431
8 Volt Reference
Channel C
Reference Voltage Feed
Transfer Case Position F14 LT GRN/BLK 431
8 Volt Reference
E7 YEL/BLK 1558 Switch Encoder Signal -
Channel B Transmission Mounted
F15 LT GRN 275 Neutral Safety Switch
Transfer Case Position Output - Park
E8 DK BLU/WHT 1557 Switch Encoder Signal -
Channel A F16 LT BLU/BLK 1693 4WD Switch Signal
Serial Data Signal - Class
E9 PPL 1807
B - 10400 BAUD - Primary
Fuse Output - Ignition 3 -
E10 BRN 241
Type III Fuse_____ ____
E11 Not Used
E12 YEL 400 VSS Signal
E13 PPL 401 VSS Return
4WD Front Wheel Lock
E14 BLK/WHT 1695 Telltale Feed
E15 Not Used
E16 BLK/WHT 451 EGM Ground
Automatic Transfer Case Module Automatic Transfer Case Select Switch,
Connector C1

E
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a i
62450

Connector Part • 12052856

Information • CONN 4F M/P 280 (BLACK) Connector Part ■ 12064766
Circuit Information “ OOiiN.8F M/P 150 (BLACK)
Pin Wire Color No. Function
Wire Color Circuit
Transfer Case Motor Pin No. Function
BLK 1552 Feed - CW
LT GRN/ Reference Voltage Feed -
A 431
Transfer Case Motor BLK 8 Volt Reference
RED 1553 Feed - CCW LT BLU/ 4WD Switch Signal
B 1693
BLK 150 Ground BLK
Fuse Output - Battery • 4 ’LO’ Indicator Lamp
ORN 1640 Type III Fuse_______ C PPL/WHT 1565 Output
4 ’HI’ Indicator Lamp
D TAN/BLK 1566 Output
LT GRN/ 2 ’HI’ Indicator Lamp
E 1563
BLK O utpi'
4WD Indicator Lamp
F PNK 1561 Output
G BLK 150 Ground
H GRY 8 IP Lamp Feed
Automatic Transfer Case Select Switch, Front Axle Actuator
Connector C2

12045813
CONN 4F M/P 150
' ; BLK

204352 Connector Part • 12077591

Connector Part • 12045813 Information •. ASM 5F M/P 150 (BLACK)
Information • CONN 4F M/P 150 (BLACK) Circuit
Wire Color No.
Circuit Pin Function
Pin Wire Color 4WD Front Wheel Lock
No. Function BLK/WHT 1695
A — — Not Used Telltale Feed
B PPL/WHT 1382 LED Dimming Signal GRY/BLK 1570 Front Axle Actuator Output
Use Output - Ignition 3 - BRN 241
Fuse Output - Ignition 3 -
C BRN 241 Type II Output_____ ___
Type III Fuse
Neutral Indicator Lamp BLK "lE fT Ground
D BRN 1560
Output
Diagnostic Information and Procedures
Tr o ubleshooting Hints (Selectable 4WD) S ys te m D ia g n o s is (A u to m a tic 4 W D )
• Make sure all mechanical components are Self-Diagnosis
operative before diagnosing the electrical portion
of the Selectable Four-Wheel Drive (S4WD) The two speed Auto transfer case system utilizes a
system. part time front axle. The system allows the driver
to select the transfer case position with a touch of a
• To determine whether the vehicle is in two-wheel button. The following positions can be selected:
drive or four-wheel drive, lift the vehicle so that 4-wheel drive high range (4H), All Wheel Drive
the wheels can spin freely. (AUTO), 2-Wheel Drive high range (2H), Neutral (N),
• Make sure that the 4WD,TGASE, GAUGES and and 4-Wheel Drive low range (4L).
ILLUM fuses are not open. If open, LOCATE The Auto Transfer Case (ATC) Control Module
and REPAIR the source of the overload and controls all the shifting action of the transfer case
replace the fuse(s). based on input from the driver as well as information
• CHECK for a broken (or partially broken) wire from the Vehicle Control Module (VCM) /Powertrain
inside of the insulation which could cause system Control Module (PCM).
failure but prove good in a continuity/voltage 4WD (4H or 4L) mode: This is accomplished by
check with a system disconnected. These circuits engaging the front axle, applying PWM to an electric
may be intermittent or resistive when loaded, motor to apply maximum torque, (fully compressing the
and if possible, should be checked by monitoring transfer case clutch plates) to the front axle, then
fuse voltage drop with the system operational removing the ground on circuit 1569, thus locking the
(underload). motor in position and stop the PWM to the motor.
• CHECK for proper installation of aftermarket AUTO mode: When in this mode of operation,
electronic equipment which may affect the integrity the system should engage the front axle, then it
of other systems. Refer to Troubleshooting monitors the front and rear propshaft speeds for any
Procedures. speed differences. When the system sen ses rear
® While performing diagnostic procedures, the wheel slip, a difference of propshaft speed between
ignition switch must be in RUN and the S4WD front and rear, the Auto Transfer Case (ATC) Control
control lever must be in the S4WD ENGAGED Module will use pulse width modulation (PWM) to
position. drive an electric motor. This motor transfers only the
required torque to the front wheels to gain additional
Troubleshooting Hints (Automatic 4WD) traction on slippery surfaces up to 75 mph. There is no
torque applied to the front wheels until the module
• Make sure all mechanical components are senses rear wheel slip.
operative before diagnosing the electrical portion
of the Automatic Four-Wheel Drive System. Throttle anticipation (only operational when in AUTO
mode): If the vehicle is below 5 mph and the
® To determine whether the vehicle is in two-wheel accelerator is pressed quickly beyond a set point, the
drive or four-wheel drive, lift the vehicle so that
system will automatically transfer a percentage of
the wheels can spin freely.
torque to the front wheels to help prevent the
• Make sure that the 4WD,TCASE, GAUGES and rear wheels from slipping, as in a hard acceleration
ILLUM fuses are not open. If open, LOCATE from a stopped position.
and REPAIR the source of the overload and
The Auto Transfer Case (ATC) Control Module also
replace the fuse(s).
has the capability of engaging the front axle while the
• CHECK for a broken (or partially broken) wire vehicle is in motion. It does this by applying PWM
inside of the insulation which could cause system to the electric motor to apply torque to the front axle,
failure but prove good in a continuity/voltage this action is used to match the speed of the front
check with a system disconnected. These circuits and rear propshafts. After the module sen ses
may be intermittent or resistive when loaded, the proper speed, it then supplies a ground on circuit
and if possible, should be checked by monitoring 1570 to engage the front axle.
fuse voltage drop with the system operational
The Auto Transfer Case (ATC) Control Module will
(under load),
accept a mode shift only when the engine is running
• CHECK for proper installation of aftermarket and a valid Motor/Encoder signal is present. A
electronic equipment which may affect the integrity mode shift is any shift between 2H, 4H, and AUTO.
of other systems. See to Troubleshooting
Procedures.
The Auto Transfer Case (ATC) Control Module will • Throttle anticipation mode
permit a range shift only if the following conditions are • Average and highest PWM applied during last
met within 30 seconds of the request:
Throttle anticipation corrective action event
• Engine running
• Difference between front and rear propshaft RPM
• Transmission in Neutral
• Adapt event counter
• Vehicle speed below 3 mph
• Throttle position sensor percentage
• Proper Motor/Encoder signal present
A range shift is a shift between high range (2H, 4H, A Scan Tool can actuate (turn on/off or change
and AUTO) and low range (4L). modes) of the following:
The Auto Transfer Case (ATC) Control Module will • Clear Auto Transfer Case (ATC) DTCs
permit a range shift into or out of Neutral only if • Service 4WD lamp (tell tail)
the following conditions are met:
• Transfer Case Lock
• Ignition ON
• All lamps in switch assembly (4WD, 2H» 4H, 4L,
Transmission in neutral and Neutral)
• Vehicle speed at zero • Front Axle
Diagnostic Aids • Request 4WD (Adapt) Mode
A Scan Tool reads and displays the following • Request 2H Mode
information:
• Request 4H Mode
• Diagnostic Trouble code(s)
• Request 4L Mode
• Code status bit (are codes set or not)
• Request Neutral
• Transfer case lock status
• Lamp in the switch/lamp assembly • Drive ATC Motor to various position. 50% PWM
max with 5 second time out with 10 second
• Motor/Encoder gear position wait before re-activating
• Ignition (3) voltage
Test Decription
• Front propshaft speed sensor (KPH)
The numbers below refer to the step numbers on the
• Front axle switch (open/closed)
diagnostic table.
• Front axle requested position
(engaged/disengaged) . . 1. This step checks the class II communication
between the ATC module and the scan tool
• Rear propshaft speed sensor (KPH)
as well as the other modules that communicate
• Mode switch position request over the Class II data bus.
• Park switch (open/closed) 4. This step checks the system operation (static) to
• 4WD (Adapt) Mode Auto bit see if it will set a DTC related to a system
• Current Mode corrective action PWM failure.
• Average and highest PWM applied during last slip 5. This step checks the Park Switch input for proper
recovery event operation.

Step Action Value(s) Yes No

1. Install a scan tool.
2. Turn the ignition switch to the ON position. Use a
scan tool in order to try to communicate with each
1 module on the Class II data bus, Auto Transfer Case —
(ATC) Control Module, Electronic Brake Control
Module (EBCM), and Vehicle Control Module (VCM),
or Powertrain Control Module (PCM). Go to DLC Pin
Does the scan tool communicate with all the modules? Go to Step 2 Assignment
Use a scan tool in order to check for any DTCs in the Go to Applicable
2
Antilock Brake System. DTC Table in the
Are there any DTCs in the Antilock Brake System? Antilock Brake
System Go to Step 3
Use a scan tool in order to check for any DTCs in the Go to Applicable
3
PCM/VCM. _ DTC Table in
Are there any DTCs in the VCM/PCM? PCM/VCM
Section Go to Step 4
 Step Action Value(s) Yes No
Check for any DTCs in the Auto Transfer Case (ATC)
4 Control Module. — Go to Applicable
Are there any Auto Transfer Case DTCs? DTC Table Go to Step 5
1. Scan tool installed.
2. Set park brake. Place transmission in Neutral.
3. Start engine and let idle.
Important: Allow time to complete the shift request before
5 requesting the nest shift. ■ —
4. With the scan tool, read the Motor/Encoder Gear
Position as you shift the transfer case through Go to
all modes. DTC C0327
Does the scan tool show the correct gear position or Encoder Circuit
requested gear position of the transfer case? Go to Step 6 Malfunction
1. Scan tool installed.
2. Park brake set and transmission in Neutral. Go to
DTC C0357 Park
3. Use the scan tool in order to read the Gear Position Switch Circuit
6 as you shift the transmission from Neutral to Park —
High or
and back to neutral. Symptom
Does the scan tool show the correct gear position or Diagnosis for
requested gear position of the transmission? Go to Step 7 park switch
1. Check for any DTCs. Road test vehicle if necessary
to identify customer complaint. While driving the
7 vehicle, shift from 2H to AUTO and 4WD. —
2. Use the scan tool in order to check for any DTCs. Go to Applicable
Are there any DTCs? DTC Table System OK

Diagnostic Trouble Codes Obtaining Diagnostic Trouble Codes

Diagnostic Trouble Code (DTC) 1 1. The diagnostic trouble codes are displayed on the
three transfer case shift select buttons. The shift
When the ignition switch is positioned to RUN the
select buttons are located on the instrument
TCCM test to determine if RAM standby Power
panel when the connector pin 13 on the data link
(maintained battery power) to the TCCM was lost since
cable is grounded, and the ignition switch has
the ignition was last turned O FF. When power is
been OFF for at least five seconds prior to
interrupted on pin C 6 of the TCCM, the TCCM stores
positioning the ignition switch to run the shift select
a loss of RAM standby power.
buttons will blink various times together in order
Diagnostic Trouble Code (DTC) 2 to indicate a diagnostic trouble code from 1 to 4.
During electronic shifting, the TCCM check the 1.1. Position the ignition switch to OFF.
motor/encoder for normal operation. If the Ensure the ignition switch Is positioned
motor/encoder does not function correctly enough to OFF for at least 6 seconds.
times, the TCCM stores a motor/encoder
1.2 . Connect pin 13 on the data link cable to a
failure DTC 2.
vehicle ground source.
Diagnostic Trouble Code (DTC) 3 The data link connector is located in the
The TCCM performs a test each time the electronic- cab under the instrument panel on
shift motor is turned ON or OFF. If the motor does the drivers side.
not function properly the TCCM stores a motor circuit 1.3. Position the ignition switch to RUN.
failure DTC 3, and the shift select buttons blink in
1.4. Note the shift select buttons for blinking
order to inform the driver of a problem.
codes. Refer to D ia g n o s tic T ro u b le C o d e s .
Diagnostic Trouble Code (DTC) 4 2. If the shift select buttons all blink one time and
Each time the ignition is turned ON, the TCCM tests stop, and do not continue to blink, no fault
the memory, the program, and the internal system codes are stored in the TCCM.
in order to ensure that the TCCM is operating properly.
If the TCCM detects a fault within the TCCM, the
TCCM stores a RAM/ROM memory failure (DTC) 4.
When the TCCM is running a diagnostic, and a code 4
is displayed by the shift select buttons, replace
the TCCM.
3. The transfer case shift select buttons will blink in Clearing Memory (Selectable 4W D)
order to identify any stored DTC. If only one code
Important: The codes will not clear if the
is stored in the TCCM memory, that code will 15-am p 4WD fuse is not removed for at least
blink repeatedly with a three second delay 30 seconds.
between blinking sequences. If more than one The code 1 will continue to occur until the ignition
code is stored, the first code will blink once, then switch is cycled from RUN to O FF five times.
after a three seconds delay, the next code will 1. Perform the following in order to clear the
blink. This sequence will continue until pin 13 is no diagnostic trouble codes (DTC) and in order
longer grounded. to clear the stored memory from the transfer case
control module (TCCM).
4. When reading the diagnostic trouble codes, the
number of shift select buttons blinks will indicate 2. Turn the ignition switch to the O FF position.
the code number. 3. Remove the 15-am p 4WD fuse.
4. Wait at least 40 seconds then replace the fuse.
5. Cycle the ignition switch from RUN to O FF
five times in order to clear the diagnostic
trouble code 1 from the TCCM.

Transfer Case Functional Test

Step Action Value(s) Yes No
1. Ensure the transmission shift select is in the PARK
position.
2. Turn the ignition switch to the OFF position for
1 6 seconds. — Go to Step 2
3. Turn the ignition switch to the RUN position and note Go to
the three transfer case shift select buttons. Functional Test
Do all three shift select buttons blink once? Failed Step 2
Did one of the shift select buttons stay lit in order to Go to
2 indicate the transfer case shift position? — Functional Test
Go to Step 3 Failed Step 4
1. Shift the transfer case to 4HI.
2. Shift the transfer case to 2HI. —
3 Go to
3. shift the transfer case back to 4HI. Functional Test
Does the transfer case mode shift between 4HI and 2HI? Go to Step 4 Failed Step 6
1. Apply the park brake.
2. For automatic transmissions, place the transmission
shift select in the PARK position.
3. For manual transmissions, shift the transmission into
first gear.
4 4. Place the ignition switch in the RUN position. —
5. Place the transfer case in the 4HI position.
6. Press the 4LO transfer case shift select button.
Does the 4LO shift select button blink for 30 seconds and Go to
the stop blinking when the 4HI shift select button Functional Test
illuminates? Go to Step 5 Failed Step 8
 Transfer Case Functional Test (cont’d;
Step Action Value(s) Yes No
1. Place the ignition switch in the RUN position.
2. Place the transfer case in the 4HI position.
3. Press the 4Lo transfer case shift select button and
note the blinking.
4. For automatic transmissions, position the
5 transmission shift select to NEUTRAL. —
5. For manual transmissions, push the clutch pedal to
the floor panel.
Does the 4LO shift select button stop blinking and stay lit
when the transmission is shifted to neutral (for automatic Go to
transmissions) or the clutch pedal is pushed in (for manual Functional Test
transmissions)? Go to Step 6 Failed Step 8
1. Press the 2HI shift select button and shift the transfer
case into 2HI.
2. For automatic transmissions, position the
transmission shift select in the PARK position.
3. For manual transmissions, position the transmission
into the first gear.
6
4. Position the ignition switch to OFF.
5. Using a wire, connect pin 13 on the data link
connector to a vehicle ground source. Test complete
transfer case
6. Position the ignition switch to RUN. electronic shift Go to
Do all three shift select buttons blink once and then system operates Functional Test
stay OFF? properly. Failed Step 9

Functional Test Failed

Step Action Value(s) Yes No
Were you sent here from Electric Shift System Go to Electric
1 Functional Test? Shift Transfer
— Go to Step 2 Case
Functional Test
Did any of the three shift select buttons blink once? Go to All Shift
2 — . Select Buttons
Go to Step 3 Do Not Light
Did one of the shift select buttons stay lit in order to
3 — ■
indicate the transfer case shift position? Go to Step 4 Go to Step 5
4 Does the transfer case mode shift between 4HI and 2HI? — Go to Step 5 Go to Step 6
1. Position the ignition switch to RUN.
2. Position the transmission to neutral. Go to Reduced
5 — Go to transfer or No Mode
3. Push the vehicle forward about five feet. case mechanical and Range
Does the transfer case mode shift between 4HI and 2HI? diagnosis. Shift Operation
Does more that one shift select button stay lit? Go to More Than Go to Reduced
One Shift Select or No Mode
6 — Button and Range
Remains Lit Shift Operation
1. Apply the park brake.
2. For automatic transmissions, place the transmission
shift select in PARK.
3. For manual transmissions, shift the transmission into
7
first gear. —
4. Position the ignition switch to RUN.
5. Press the 4LO transfer case shift select button.
Does the 4LO shift select button blink for 30 seconds? Go to Step 8 Go to Step 9
 Functional Test Failed (cont’d)
Step Action Value(s) Yes No
1. Position the ignition switch to RUN.
2. Press the 4LO transfer case shift select button and
note the blinking.
3. For automatic transmissions, position the
transmission shift select to neutral.
8 — '
4. For manual transmissions, push the clutch pedal to
the floor panel.
Does the 4LO shift select button stop blinking and stay lit Go to Reduced
when the transmission is shifted to neutral (automatic Go to Perform a or No Mode
transmissions) or when the clutch pedal is pushed in Diagnostic On and Range
(manual transmissions)? the TCCM Shift Operation
Does the transfer case range shift to 4LO? Go to Reduced
Go to All Shift or No Mode
9 — Select Buttons and Range
Remain Lit Shift Operation

All Shift Select Buttons Do Not Light

Step Action Value(s) Yes No
Were you sent here from a diagnostic table? Go to Electric
1 Go to Step 2 Shift Transfer
___ Case
Functional Test
1. Check the 10 AMP Illumination fuse (number 5) in the
IP fuse block for an open.
2. Check the 10 AMP power fuse (number 15) in the
2 IP fuse block for an open. —
3. Check the 20 Amp ATC fuse in the underhood Go to All Shift
bussed electrical center (UBEC) for an open. Select Buttons
Is one of the fuses open? Go to Step 3 Remain Lit
1. Replace the fuse.
2. Turn the ignition switch to the RUN position.
3 3. Check the operation of the electronic shift system. — Go to Electric
Shift Transfer
4. Check the fuse for an open. Case
Is the fuse open? Go to Step 4 Functional Test
1. Turn the ignition switch to the OFF position.
2. Check pins C1 and C2 on the shift select switch for a
4 ground if fuse 5 or 15 in the IP block was open. —
3. Check CKT 1640 for a ground if the ATC fuse
was open. .
Was one of the CKT grounded? Go to Step 5 Go to Step 6
1. Position the ignition switch to OFF.
2. Repair the grounded CKT. Go to Electric
5 — Shift Transfer —
3. Replace the fuse. Case
Is the repair completed? Functional Test
Check pin A on the back of the shift select switch for B+
6 voltage. —
Is B+ voltage on pin A? Go to Step 8 Go to Step 7
1. Open wire in CKT 1220 between the fuse and pin C1,
or CKT 241 between the fuse and pin C2.
7 2. Repair the open. — Go to Electric
Shift Transfer
3. Check for loose electrical connectors. Case
Is the repair complete? Functional Test
 All Shift Select Buttons Do Not Light (cont’d)
Step Action Value(s) Yes No
1. Position the ignition switch to RUN.
2. Do not unplug the harness connector from the shift
select switch.
3. Depress all three shift select buttons as the following
8 —
pins are checked for B+ voltage.
4. Check pins A, B, and F on the back of the shift select
switch for B+ voltage.
Is B+ voltage at pin A, B, or F? Go to Step 9 Go to Step 10
1. Position the ignition switch to OFF.
9 2. Ensure pin D10 on the TCCM is grounded. —
Is pin D10 grounded? Go to Step 12 Go to Step 11
1. Position the ignition switch to OFF. Go to Electric
Shift Transfer
10 2. Replace the shift select switch. — Case —
Has the shift select switch been replaced? Functional Test
1. An open in CKT 1050 between pin D10 and ground. Go to Electric
Shift Transfer
11 2. Repair the open in CKT 1050. — Case —-
Is the repair completed? Functional Test
Check pins C6 and C8 on the TCCM for B+ voltage. Go to Perform a
12 Is B+ voltage at pins C6 and C8? — Diagnostic On
the TCCM Go to Step 13
1. If no B+ is on C6, an open exists on CKT 40 between
the fuse and pin C6 on the TCCM.
Go to Electric
13 2. If no B+ is on C8, an open exist on CKT 241 — Shift Transfer —-
between the fuse and pin C8 on the TCCM. Case
Is the open repaired? Functional Test

One or Two Shift Select Buttons Do Not Light

Step Action Value(s) Yes No
Were you sent here from a diagnostic table? Go to Electric
1 — Shift Transfer
Case
Go to Step 2 Functional Test
Position the ignition switch to OFF for at least 6 seconds. Go to Reduced
2 Position the ignition switch to RUN. or No Mode and
— Range Shift
Can mode and range shifts be made?
Go to Step 3 Operation
1. If the 2H1 button will not light, check for and open on
CKT 1563 between pin G on the shift select switch
and pin C11 on the TCCM.
2. If the 4H1 button will not light, check for an open on
CKT 1566 between pin F on the shift select switch
3 and pin C12 on the TCCM. —
3. If the 4L0 button will not light, check for an open on
CKT 1565 between pin E on the shift select switch
and pin C14 on the TCCM.
Is an open found on the CKT checked Go to Step 4 Go to Step 5
Repair the open CKT. Go to Electric
4 Is the repair completed? Shift Transfer —
— Case
Functional Test
 One or Two Shift Select Buttons Do Not Light (cont’d)
Step Action Value(s) Yes No
1. If 2H1 does not light, check for B+ voltage at pin C11
on the TCCM.
2. If 4H1 does not light, check for B+ voltage at pin C12
5 on the TCCM. —
3. If 4L0 does not light, check for B+ voltage at pin C14
on the TCCM.
Is B+ voltage at the checked pin? Go to Step 8 Go to Step 6
1. If 2H1 does not light, check for a open in CKT 1563
between pin G on the shift select switch and pin C11
on the TCCM.
2. If 4H1 does not light, check for an open in CKT 1566
between pin F on the shift select switch and pin C12 —
6 on the TCCM.
3. If 4L0 does not light, check for an open in CKT 1565
between pin E on the shift select switch and pin C14
on the TCCM.
Is the checked CKT open? Go to Step 7 Go to Step 8
1. Position the ignition switch to OFF. Go to Electric
Shift Transfer
7 2. Repair the open in the CKT. — Case —
Is the repair completed? Functional Test
1. Position the ignition switch to OFF.
2. If 2H1 does not light, position a jumper from pin C11
to a vehicle ground source.
3. If 4H1 does not light, position a jumper from pin C12
8 to a vehicle ground source. —
4. If 4L0 does not light, position a jumper from pin C14
to a vehicle ground source.
Go to Perform a
5. Position the ignition switch to RUN. Diagnostic On
Does the shift select button light? the TCCM Go to Step 9
Replace the shift select switch. Go to Electric
Has the switch been replaced? Shift Transfer
9 — Case —
Functional Test

All Shift Select Buttons Remain Lit

Step Action Value(s) Yes No
Were you sent here from a diagnostic table? Go to Electric
Shift Transfer
1 — Case
Go to Step 2 Functional Test
1. Position the ignition switch to OFF for at least
6 seconds.
2 —
2. Position the ignition switch to RUN.
Can any mode or range shifting be made? Go to Step 3 Go to Step 8
3 Can shift modes (2H1 to 4H1 to 2H1) be made? — Go to Step 4 Go to Step 7
1. Position the ignition switch to RUN.
4 2. Check for B+ voltage at pins D2 and D16 on — Go to Perform a
the TCCM. Diagnostic On
Was B+ voltage on both pins? the TCCM Go to Step 5
 All Shift Select Buttons Remain Lit (cont’d)
Step ction Value(s) Yes No
1. Position the ignition switch to OFF.
2. Check for an open between CKT 1737 and D16 on
the TCCM.
5 —
3. Check for an open between CKT 275 and D2 on Go to Perform
the TCCM. a Diagnostic
Was an open found on one of the CKT? Go to Step 6 On the TCCM
1. Ensure the ignition switch is positioned to OFF. Go to Electric
6 Shift Transfer
2. Repair the open in the CKT. — Case —
Is the repair completed? Functional Test
1. Position the ignition switch to RUN.
2. If 2H1 can not be selected, check for an open on
CKT 1562 between pin C4 on the TCCM and Pin B
on the shift select switch.
7 —
3. If 4H1 can not be selected, check for an open on
CKT 1564 between pin C5 on the TCCM and pin C Go to Perform
on the shift select switch. a Diagnostic
Was an open found on one of the CKT? Go to Step 6 On the TCCM
1. Position the ignition switch to RUN.
8 2. Check for an open on CKT 1555 between pin D5 on — Go to Perform
the TCCM and pin C on the motor/encoder. a Diagnostic
Was an open found on CKT 1555? Go to Step 6 On the TCCM

More Than One Shift Select Button Remains Lit

Step Action Value(s) Yes . No
Were you sent here from a diagnostic table? Go to Electric
1 — Shift Transfer
Case
Go to Step 2 Functional Test
1. If 2H1 remains lit, check for a ground in CKT 1563
between pin C on the shift select switch and pin C11
on the TCCM.
2. If 4H1 remains lit, check for a ground in CKT 1566
2 between pin F on the shift select switch and pin C12
on the TCCM. —
3. If 4L0 remains lit, check for a ground in CKT 1565
between pin E on the shift select switch and pin C14 Go to Perform
on the TCCM. a Diagnostic
Is the checked CKT grounded? Go to Step 3 On the TCCM
1. Ensure the ignition switch is positioned to OFF. Go to Electric
3 Shift Transfer
2. Repair the ground in the CKT. — Case —
Is the repair completed? Functional Test

No Shift Select Buttons Remain Lit

Step Action Yalue(s) Yes No
Were you sent here from a diagnostic table? Go to Electric
1 Shift Transfer
— Case
Go to Step 2 Functional Test
Check for an open in CKT 1554 between pin A on the Go to Perform
2 motor/encoder and pin C9 on the TCCM. — a Diagnostic
Is CKT 1554 open? Go to Step 3 On the TCCM
1. Ensure the ignition switch is positioned to OFF. Go to Electric
3 — Shift Transfer
2. Repair the open in the CKT 1554. Case —
Is the repair completed? Functional Test
 Reduced or No M ode and Range Shift Operation
Step Action Vaiue(s) Yes No
Were you sent here from a diagnostic table? Go to Electric
Shift Transfer
1 — Case
Go to Step 2 Functional Test
1. Ensure the electrical harness connector and pins to
the motor/encoder are clean and not corroded.
2. Ensure the electrical harness connector to the
motor/encoder is properly installed.
3. Check the following CKT between the motor/encoder
2 and the TCCM. —
4. Check for opens and grounds on CKT 31, CKT 940,
CKT 1552, CKT 1553 and CKT 1555.
5. Check for opens and grounds on CKT 1556, Go to Perform
CKT 1557 and CKT 1558. a Diagnostic
Are any opens or grounds found on any of the CKT? Go to Step 3 On the TCCM
1. Ensure the ignition switch is position to OFF. Go to Electric
. _ Shift Transfer ..
3 2. Repair the open or ground in the CKT. .
Case
—

Is the repair completed? Functional Test

Perform a Diagnostic On the TCCM

Step Action Value(s) Yes No
Were you sent here from a diagnostic table? Go to,Electric
Shift Transfer
1 — ■■ Case
Go to Step 2 Functional Test
Perform a diagnostic on the TCCM. Go to Obtaining
2 .... — — —
Stored Diagnostic Trouble Codes (DTC) in this section.

Four-Wheel-Drive Does Not Disengage (Selectable 4WD)

Step cion Vaiue(s) ■ Yes No
1. Place the transfer case in the RWD position.
Replace the
1 2. Disconnect the transfer case switch. — transfer case
Did the S4WD disengage? switch. Go to Step 2
Disconnect the front axle actuator. Repair the short
2 Did the S4WD disengage? -- to battery in Replace the front
CKT 1296. axle actuatoi

Four-Wheel-Drive Does Not Engage (Selectable 4WD)

Step : ctior Value(s) Yes No
DEFINITION: 4WD Will Not Engage
Disconnect Front Axle Actuator. Place Transfer Case
Select Switch in 4WD. Connect a test lamp from Front Check for open
1 Axle Actuator Terminal B to ground with the Ignition Switch ' CKT 150. If OK,
in Run. REPLACE Front
Does the test lamp light? Axle Actuator. Go to Step 2.
Disconnect Transfer Case Switch. Connect a test lamp
from Terminal A for CKT 241 to ground with Ignition
2 Switch in RUN. —
Repair Open in
Does the test lamp light? Go to Step 3. CK M \
Connect a fused jumper between CKT 241 and CKT 1296
of Transfer Case Switch. Connect a test lamp from
3 Terminal B to ground and the Front Axle Actuator with the — REPLACE the
Ignition Switch in the RUN position. Transfer Case REPAIR open in
Does the test lamp light? Switch. CKT 1296.
 Four-Wheel-Drive Indicator Does Not Light (Selectable 4WD)
Step Action Value(s) Yes No
1. Disconnect the S4WD indicator lamp. Check for an
2. Place the transfer case switch to S4WD. open in
Check or replace CKT 1695.
t 3. With the ignition switch in RUN, connect a test lamp _
the bulb.
from terminal B to ground. If OK, replace
If OK, repair the the front axle
Does the test lamp illuminate? open in CKT 150. actuator.

Four-Wheel-Drive Indicator Does Not Turn Off (Selectable 4WD)

Step Action Value(s) Yes No
1. Place the transfer case in the RWD position.
Replace the Repair the short
1 2. Disconnect the Transfer Case Switch. — transfer case to battery in
Did the Indicator Lamp go off? switch. CKT 1296.

Transfer Case Electronic Shift System T ra n s fe r Case D ia g n o s is (S e le c ta b le 4 W D )

Diagn o sis (Selectable 4WD) N o tic e ; Make any repairs that are necessary to
Make any repairs that are necessary to
N o tic e : correct the operation of electric shift system. After
correct the operation of electric shift system. After making repairs, clear the TCCM memory and perform
making repairs, clear the TCCM memory and perform the functional test in order to ensure the electric
the functional test in order to ensure the electric shift system operates properly.
shift system operates properly. 1. Prior to performing the electronic shift system
functional test, perform a TCCM diagnostic test
I m portant:Perform a TCCM diagnostic test in order
in order to ensure the TCCM is operating properly.
to ensure the TCCM is operating properly before
Refer to O b ta in in g D ia g n o s tic T ro u b le C o d e s .
performing the electronic shift system functional test.
If DTC 4 is stored in the TCCM memory, replace
1 . If DTC 4 is stored in the TCCM memory,
the TCCM.
replace the TCCM.
2 . Use the following is information that may help you
2. Use the following is information that may help you
understand some of the terminology used in the
understand some of the terminology used in the
diagnostic tables:
diagnostic tables:
® The ignition switch to the RUN position.
• The ignition switch to the RUN position.
Position the ignition switch from OFF to RUN
Position the ignition switch from OFF to RUN
but do not start the engine.
but do not start the engine.
• The ground source refers to any exposed
• The ground source refers to any exposed
metal surface on the vehicle connected directly
metal surface on the vehicle connected directly
or indirectly to the negative terminal of the
or indirectly to the negative terminal of the
battery.
battery.
• The shift select refers to the selector that
• The shift select refers to the selector that
positions or shifts the automatic transmission or
positions or shifts the automatic transmission or
the transfer case.
the transfer case,
• The blinking refers to flashing light passing
• The blinking refers to flashing light passing
through the red plastic shift select buttons.
through the red plastic shift select buttons.
• Shift the transfer case refers to pressing one
• Shift the transfer case refers to pressing one
of the three shift select buttons to shift the
of the three shift select buttons to shift the
transfer case into either 2W, 4HI, or 4LO.
transfer case into either 2HI, 4H I , or 4LO.
Repair Instructions
Oil R e p la c e m e n t
Removal Procedure
1. Raise and support the vehicle. Refer to Vehicle
Lifting Caution in General Information.
2. Place a container under the drain plug in order to
catch the oil.
3. Remove the fill plug.
4. Remove the drain plug. Allow the oil to drain.
Installation Procedure
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1. Install the drain plug.
Tighten
• Tighten the New Venture Gear drain plugs to
47 N-m (35 Ib ft).
• Tighten the Borg-W am er drain plugs to
25 N-m (181b ft).
2. Install the transfer case oil. Refer to Approximate
Fluid Capacities.
3. Fill the transfer case until the oil level is at the
bottom of the oil fill plug hole.
4. Install the fill plug.
Tighten
• Tighten the New Venture Gear drain plugs to
47 N-m (35 Ib ft).
• Tighten the Borg-W amer drain plugs to
25 N-m (18 Ibft).
5. Lower the vehicle.

Shield Replacement
Removal Procedure
1. Raise and support the vehicle.
2. Remove the four bolts and the nuts securing the
transfer case shield to the frame.
3. Remove the shield from the frame.
 Installation Procedure
1. Install the shield to the frame.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
2. Install the four bolts and the nuts securing the
transfer case shield to the frame.
Tighten
Tighten the bolts and the nuts to 35 N-m (26 Ib ft).
3. Lower the vehicle.

175368

Shift Cable Replacement

1. Place the shift lever in the 4HI position.
2. Raise and support the vehicle.
3. Disconnect the linkage rod from the console
shift lever.
4. Shift the transfer case into 4HI position (the
transfer case shift lever in full forward detent).
A click sound indicates that the transfer case lever
is all the way back.

175376

5. Adjust the swivel in order to align with the notch

in the console shift lever.
6 . Connect the linkage rod to the console shift lever.
7. Lower the vehicle.

175315
Shift Lever Replacement - On Vehicle
Removal Procedure
1. Remove the shift knobs from the transfer case
shift lever.
2. Remove the four screws securing the transfer
case shift control bezel to the floor panel
bracket and the shift bracket.
3. Remove the wiring harness from the transfer case
shift control bezel.
Raise and support the vehicle. Refer to L iftin g a n d
in General Information.
J a c k in g th e V e h ic le

4. Remove the shift lever end from the transfer case

linkage rod.

5. Remove the four bolts securing the transfer case

shift control to the floor panel bracket.
 Installation Procedure
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1 . Install the four bolts securing the transfer case
shift control to the floor panel bracket.
Tighten
Tighten the transfer case control bolts to
11 N-m (97 Ib in).

175387

2. Install the shift lever end to the transfer case

linkage rod.
Lower the vehicle.

3. Install the wiring harness to the transfer case shift

control beze l .
4. Install the four screws securing the transfer case
shift control bezel to the floor panel bracket and
the shift bracket.
Use the locator pin on the transfer case shift
control bezel in order to aid in positioning the bezel
onto the brackets.
Tighten
Tighten the transfer case shift control bezel
screws to 2 N-m (18 Ib in).
5. Install the shift knob to the transfer case
shift lever.

175319
T ra n s fe r C a s e O u tp u t S h a ft S eal
R e p la c e m e n t (N e w V e n tu re )
Removal Procedure
1. Raise the vehicle. Refer to L iftin g a n d J a c k in g th e
V e h ic le in General Information.
2. Remove the front or the rear propeller shaft. Refer
to P r o p e lle r S h a f t R e p la c e m e n t (F r o n t A x le - AH
E x c e p t N P 8 ) or P r o p e lle r S h a ft R e p la c e m e n t
( S y s te m B a la n c e d A s s e m b ly ) in Propeller Shaft.
3. Remove the propeller shaft yoke nut and the flat
washers.
4. The yoke nut and the flat washers are not used at
the rear on some models.
5. Remove the propeller shaft yoke.
6 . Remove the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
7. Remove the seal.
• Use a screwdriver in order to remove the seal.
• Do not damage the sealing bore.

175414

Installation Procedure
Tools Required
J 29162
1. Install the seal.
1.1. Lubricate the seal lips with petroleum jelly
or with transmission oil.
1.2. Install the seal using the J 33843
1.3. For all of the vehicles except the K30 with
dual rear wheels, install the New Venture
Gear transfer case.
2 . Install the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
3. Install the propeller shaft yoke.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
4. Install the flat washers and the nut, if used.
Tighten 175414
Tighten the New Venture Gear propeller shaft
yoke nuts to 149 N-m (110 Ib ft).
5. Install the propeller shaft.
• Check the transfer case oil level and add oil as
necessary. Refer to A p p r o x im a te F lu id
C a p a c itie s .
• Lower the vehicle.
Transfer Case Output Shaft Seal
Replacement (Borg-Warner)
Removal Procedure
Important: This procedure applies to the front output
shaft seal replacement and to the rear output shaft
seal replacement.
1. Raise the vehicle. Refer to L ifting a n d J a c k in g th e
V e h ic le in General Information.
2. Remove the front or the rear propeller shaft. Refer
to P r o p e lle r S h a ft R e p la c e m e n t (F r o n t A x le - A ll
E x c e p t N P 8 ) or P r o p e lle r S h a ft R e p la c e m e n t
(S y s te m B a la n c e d A s s e m b ly ) in Propeller Shaft.
3. Remove the propeller shaft yoke nut and the flat
washers.
The yoke nut and the flat washers are not used at
the rear on some models.
4. Remove the propeller shaft yoke.
5. Remove the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
6. Remove the seal.
Use a screwdriver in order to remove the seal. Do
not damage the sealing bore.
Installation Procedure
Tools Required
J 29162 Front Output Shaft Seal Installer
(NV241 Transfer Case)
1. Install the seal using the following procedure:
1.1. Lubricate the seal lips with petroleum
jelly or with transmission oil.
1.2. Install the seal using the J 2 9 1 6 2
1.3. For the K30 with dual rear wheels, install
the Borg-Warner transfer case.
2. Install the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
3. Install the propeller shaft yoke.
N o t i c e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
4. Install the flat washers and the nut, if used.
Tighten
• Tighten the rear propeller shaft yoke nuts to
170 N-m (125 Ibft).
• Tighten the front propeller shaft yoke nut to
225 N-m (165 Ib ft).
5. Install the propeller shaft.
• Check the transfer case oil level and add oil as
necessary. Refer to A p p r o x im a te F lu id
C a p a c itie s .
• Lower the vehicle.

Rear Extension Housing Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to L iftin g a n d
J a c k in g th e V e h ic le in General Information.
2. Remove the rear propeller shaft. Refer to P r o p e lle r
S h a ft R e p la c e m e n t ( S y s te m B a la n c e d A s s e m b ly )
in Propeller Shaft.
3. Remove the yoke.
4. Remove the four bolts that secure the rear
extension housing to the rear retainer housing.
Remove the rear extension housing from the rear
retainer housing.
Tap the extension housing with a rubber mallet in
order to free the rear retainer housing.

2233

5. Remove the rear bearing retainer snap ring.

6. Remove the five bolts securing the rear retainer
housing to the transfer case.
7. Remove the rear retainer housing.
8. Remove the seal.
Use a screwdriver. Do not damage the
sealing bore.
9. Clean the gasket surfaces with a suitable solvent.
Installation Procedure
1. Install the rear retainer housing.
• Make sure the gasket surfaces are clean and
free of grease and oil.
• Apply the RTV sealer GM P/N 12345739 to the
rear retainer housing sealing surfaces.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
2 . Secure the rear retainer housing to the transfer
case with the five bolts.
Apply GM P/N 12345382 or the equivalent to the
threads of the bolts.
Tighten
Tighten the rear retainer housing bolts to
40 N-m (30 Ib ft).
3. Install the snap ring.
4. Install the rear extension housing to the
transfer case.
• Clean the gasket surfaces thoroughly.
• Apply RTV sealer GM P/N 12345739 to the
rear extension housing sealing surfaces.
5. Install the four bolts that secure the rear extension
housing to the rear retainer housing.
Apply GM P/N 12345382 or the equivalent to the
threads of the bolts.
Tighten
Tighten the rear extension housing bolts to
31 N-m (23 Ib ft).
6 . Install the sea l .
• Lubricate the seal lips with transmission oil or
with petroleum jelly.
• Install the seal using the J 2 9 1 6 2
7. Install the rear propeller shaft and the yoke.
• Check the transfer case oil level. Add oil if
necessary. Refer to Approximate
F lu id C a p a c itie s .
• Lower the vehicle.
Transfer Case Replacement
(Selectable Four Wheel Drive)
Removal Procedure
1. Raise and support the vehicle. Refer to L iftin g a n d
J a c k in g th e V e h ic le in General I nformation.
2. Remove the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
3. Remove the front propeller shaft. Refer to
P r o p e lle r S h a ft R e p la c e m e n t - T w o -P ie c e
in Propeller Shaft.
4. Remove the rear propeller shaft. Refer to P r o p e lle r
S h a ft R e p la c e m e n t (S y s te m B a la n c e d A s s e m b ly )
in Propeller Shaft.
5. Disconnect the vehicle speed sensor electrical
connector.
6 . Disconnect the wiring harness from the
transfer case.
175384

7. Remove the transfer case motor/encoder.

Support the transfer case with a jack.

8 . Remove the bolts securing the transfer case to

the transmission adapter.
9. Remove the gasket.

175410
10. Discard the gasket.

Installation Procedure
1 . I nsta ll a new gasket to the transmission. Use a
gasket sealer in order to hold the gasket in place.

2. Install the transfer case to the transmission

adapter.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.

3. Install the bolts that secure the transfer case to

the transmission adapter.
Tighten
Tighten the bolts to 45 N-m (33 Ib ft).

4. Install the transfer case motor/encoder.

5. Remove the jack from the transfer case.
6 . Install the electrical connectors and the wiring
harness to the transfer case with the new
straps.
7. Install the rear propeller shaft. Refer to P r o p e lle r
S h a f t R e p la c e m e n t (S y s te m B a la n c e d A s s e m b ly )
in Propeller Shaft.
8 . Install the front propeller shaft. Refer to P r o p e lle r
S h a ft R e p la c e m e n t (F r o n t A x le - A ll E x c e p t N P 8 )
in Propeller Shaft.
9. Install the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
• Check the transfer case lubricant level. Add oil
as necessary. Refer to A p p r o x im a te F lu id
C a p a c itie s .
• Lower the vehicle.

Transfer Case Replacement

(Manual Four Wheel Drive)
Removal Procedure
1. Raise the vehicle. Refer to L iftin g a n d J a c k in g th e
V e h ic le in General Information.
2 . Remove the propeller shafts. Refer to P r o p e lle r
and P r o p e lle r S h a ft
S h a f t R e p la c e m e n t ( R e a r )
R e p la c e m e n t (F ro n t) in Propeller Shaft.
3. Disconnect the vehicle speed sensor electrical
connector.
4. Disconnect the wiring harness from the
transfer case.

175384
5. Disconnect the transfer case shift cable at the
transfer case.
Support the transfer case with a jack.

6 . Remove the bolts securing the transfer case to

the transmission adapter.
7. Remove the gasket.

8 . Discard the gasket.

Installation Procedure
1. Install a new gasket to the transmission. Use a
gasket sealer in order to hold the gasket in place.

2. Install the transfer case to the transmission

adapter.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
3. Install the bolts that secure the transfer case to
the transmission adapter.
Tighten
Tighten the bolts to 45 N-m (33 Ib ft).
4. Remove the jack from the transfer case.
5. Install the transfer case shift linkage at the
transfer case.
6 . Install the electrical connectors and the wiring
harness to the transfer case with the new
straps.
7. Remove the propeller shafts. Refer to P r o p e lle r
S h a ft R e p la c e m e n t ( R e a r ) and P r o p e lle r S h a f t
R e p la c e m e n t (F ro n t) in Propeller Shaft.
• Check the transfer case lubricant level. Add oil
as necessary. Refer to L u b ric a tio n
S p e c ific a tio n s .
• Lower the vehicle.

Adapter Replacement
Removal Procedure
1. Remove the transfer case. Refer to T r a n s fe r C a s e
R e p la c e m e n t ( M a n u a l F o u r W h e e l D riv e ).
2. Remove the bolts securing the adapter to the
transmission.
3. Raise the rear of the transmission slightly.
4. Remove the adapter from the transmission.
5. Remove the seal.
 Installation Procedure
1 . Install the new seal to the transmission.
Lubricate the seal lips with the transmission oil or
the petroleum jelly.
2. Install the adapter to the transmission.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
3. Install the six bolts securing the adapter to the
transmission.
Tighten
Tighten the adapter bolts to 45 N-m (33 Ib ft).
4. Install the transfer case. Refer to T r a n s fe r C a s e
R e p la c e m e n t ( M a n u a l F o u r W h e e l D riv e ).

Motor/Encoder Replacement
(Selectable 4WD)
Removal Procedure
1. Remove the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
2. Remove the transfer case wiring harness
connectors from the motor/encoder.

177160

3. Remove the four bolts that secure the

motor/encoder to the transfer case.
Installation Procedure
1 . Install the with a motor/encoder.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
2. Install the four bolts securing the motor/encoder to
the transfer case.
Tighten
Tighten the motor/encoder bolts to
25 N-m (18 Ib ft).
• Remove all gasket material remaining from the
motor/encoder.
• Ensure the motor/encoder aligns properly with
the transfer case interior shifting components.
• Align the motor/encoder mating surface detent
with the transfer case mating surface detent.

177164

3. Install the wiring harness connectors to the

motor/encoder.
4. Install the transfer case shield. Refer to S h ie ld
R e p la c e m e n t.
5. Perform a functional test on the electronic shift
select system in order to test the motor/encoder.
Refer to T r a n s fe r C a s e F u n c tio n a l T est.

177160

Transfer Case Driver Control Switch

Replacement (Selectable 4WD)
Removal Procedure
1. Remove the shift select switch from the
instrument panel.
• Pull the tabs on the rear of the switch in.
• Pull the switch straight out from the panel.
2 . Remove the electrical connector from the shift
select switch.

177180
 Installation Procedure
1 . Install the electrical connector to the shift select
switch.
2. Install the shift select switch into the
instrument panel.
Ensure the shift select switch locks into the
instrument panel.

Transfer Case Control Module

Replacement (Auto Transfer Case)
Removal Procedure
1. Remove the lower instrument panel trim.
2. Remove the two screws securing the transfer
case control module to the bracket.
The bracket is mounted on the l/P reinforcement.
3. Remove the electrical connector from the transfer
case control module.

Installation Procedure
1. Install the electrical connector to the transfer case
control module.
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
2 . Install the two screws securing the transfer case
control module to the bracket.
Tighten
Tighten the transfer case control module screws
to 8 N-m (71 Ib ft).
3. Install the lower instrument panel trim.

177176
Speed Sensor Replacement
(Front Speed Sensor Replacement)
Removal Procedure
1. Remove the electrical connector from the speed
sensor.
2. Remove the front speed sensor from the
transfer case.

163707

Installation Procedure
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1. Install the front speed sensor into the
transfer case.
Tighten
Tighten the front speed sensor to
31 N-m (23 Ibft).
2. Install the electrical connector to the speed
sensor.

Speed Sensor Replacement

(Rear Speed Sensor Replacement)
Removal Procedure
1. Remove the two electrical connectors from the
two rear speed sensors.
2. Remove the two rear speed sensors from the
transfer case.

163714
Installation Procedure
N o tic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1. Install the two rear speed sensors to the
transfer case.
Tighten
Tighten the rear speed sensors to
31 N-m (23 Ibft).
2 . Install the two electrical connectors to the two rear
speed sensors.

Transfer Case Electrical Connector

Replacement (Selectable 4WD)
Removal Procedure
Remove the four electrical connector from the speed
sensors and the motor/encoder.
Installation Procedure
Install the four electrical connector to the speed
sensors and the motor/encoder.

Description and Operation

Transfer Case Description
(Selectable 4WD)
The transfer case is used to provide power flow from
the transmission to the front axle. The transfer
case also provides a way of disconnecting the front
axle in order to provide better fuel economy and
quieter operation when the vehicle is driven on the
roads where the four-wheel drive is not required. The
transfer case provides an additional gear reduction
when placed in low range. This is useful when difficult
off-road conditions are encountered.
The New Venture Gear Models NV241 or NV243
transfer case is used on all of the four-wheel drive
vehicles under 9200 Ib GVW. The NV243 is similar to
the NV241 except that it contains an electric shift
motor/encoder attached to the transfer case in the area
where the shift lever is ordinarily mounted.
The K30 Models with single or dual rear wheels will 5. The thermal actuator contains a heating element,
use the Borg-W am er Models 4401 or 4470 transfer a gas charge, and a piston.
case. Both of these transfer cases use a shift lever and When the current is applied, the heating element
a shift linkage in order to change the operating range. heats the gas. The gas expands, pushing the
The Models N V241, 4401, and 4470 are aluminum piston out after a delay of a few seconds.
case, chain driven units w ith four modes of operation; The piston actuates the shift fork in the front axle.
neutral, two wheel drive high range, four wheel This connects the right axle output shaft to the
drive high range, and four wheel drive low range. The front axle differential. The torque is then available
gear reduction for low range is provided by a at the front wheels.
planetary gear set. 6 . The front axle shift mechanism, when fully
A floor mounted shift lever is used in order to select engaged, closes a switch, causing the front
the operating range for the NV241, the 4401, and ax le indicator lamp to come ON.
the 4470. The indicator lamps on the floor console 7. If the shift lever is moved back to the 2 W HEEL
show the current mode of operation. When four-wheel position, the operations in the preceding steps
drive indicator lamp is designed to come ON are reversed. The current to the thermal actuator
whenever the front axle has engaged. A slight delay is turned OFF. The gas cools and the piston
for the front axle indicator lamp to come ON is normal. retracts allowing the shift fork in the front axle in
The New Venture Gear Model N V243 is electronically order to return to the two-wheel drive position.
actuated. The vehicles equipped with this model
have no transfer case selector lever. The operator
Four-Wheel Drive Low Range Operation
selects 2HI, 4HI, or 4LO by pushing one of three When the transfer case is shifted into the 4LO position,
switches mounted on the instrument panel. During the torque flow and the operation is similar to the
normal driving the transfer case is in the 2HI mode. 4HI range, except that the range shift hub engages the
When the transfer case is in 2HI both the 4HI and the planetary carrier. The planetary gear set then
4LO switch circuits are open, and both lights are provides a gear reduction to the front and the
OFF. When the four-wheel drive has been selected, rear axles.
the four-wheel drive indicator lamp on the switch turns
Electronic Synchronizer Operation
on when the front axle has engaged. The lamp will
blink while the front axle is engaging. For more
(Borg-Wamer)
information on the electrica l operation of the NV243, The electronic synchronizer is used in model 4401
refer to T ra n s fe r C a s e S y s t e m D e s c rip tio n and 4470 transfer cases in order to provide smoother
(S e le c t a b le 4 W D ) . shifting. The system requires no maintenance or
service.
Two-Wheel Drive Operation
The system consists of a relay and a clutch coil
When the transfer case is in the 2 W HEEL range, the (electromagnet) inside the transfer case. The clutch
torque flows from the input gear to the range shift coil replaces the conventional blocker ring. When
hub and the main shaft, through the propeller shaft to energized, the clutch coil provides synchronization,
the rear axle. resulting in a smooth shift. When the transfer
2HI to 4HI case lever is moved to 4HI or 4LO position, the
current is supplied to the normally closed relay. The
Important: Shifting into the 4HI range causes the current flows through the relay to the clutch coil, when
following conditions to occur. the front axle engages, the axle switch energizes
1. The front axle indicator lamp does not come on the relay coil. The relay switch then opens, and the
until the front axle engages. current to the clutch coil is interrupted.
2. The torque flows from the input gear to the Identification
mainshaft the same as in the two-wheel position.
For New Venture Gear Transfer Cases, an
The shift linkage moves the mode synchronizer identification tag is attached to the rear case half. The
sleeve into engagement with the clutch teeth of the tag provides the transfer case model number, the
drive sprocket. This locks the drive sprocket to low range reduction ratio, and the assembly part
the mainshaft through the synchronizer sleeve. number.
3. The torque is transmitted through the drive For the Borg-Warner Transfer Cases, an identification
sprocket and the drive chain to the driven sprocket tag is attached to an extension housing bolt. The
and the output shaft. The torque then flows tag provides the transfer case model number,
through the front propeller shaft to the front axle. the serial number, a build date, and a low range
4. The shift mechanism in the transfer case closes reduction ratio.
the transfer case switch.
The current is then applied to the front axle
thermai actuator and the front axle switch. In the
K30 vehicles, the power is also supplied by
the transfer case relay to the transfer case
synchronizer.
Transfer Case System Description Throttle anticipation (only operational when in AUTO
(Selectable 4WD) mode): If the vehicle is below 5 mph and the
accelerator is pressed quickly beyond a set point, the
The New Venture Gear Model NV243 is an system will automatically transfer a percentage of
electronically controlled optional transfer case for use torque to the front wheels to help prevent the
on four wheel drive K trucks. The driver selects rear wheels from slipping, as in a hard acceleration
2HI, 4HI, or 4LO by pushing one of three illuminating from a stopped position.
shift select buttons mounted on the instrument
The Auto Transfer Case (ATC) Control Module also
panel. The shift se lect buttons display the transfer
has the capability of engaging the front axle while the
case mode and range, self-test, diagnostic trouble
vehicle is in motion. It does this by applying PWM
codes, and electronic shift mechanical engaging
to the electric motor to apply torque to the front axle,
problems.
this action is used to match the speed of the front
During normal driving the transfer case is in the 2HI and rear propshafts. After the module sen ses
mode. When the transfer case is in the 2HI mode. the proper speed, it then supplies a ground on circuit
When the transfer case is in 2HI both the 4HI and 4LO 1570 to engage the front axle.
switch circuits are open, and both lights are OFF.
The Auto Transfer Case (ATC) Control Module will
When the four-wheel drive shift select button has been
accept a mode shift only when the engine is running
pressed, the four-wheel drive indicator lamp under
and a valid Motor/Encoder signal is present. A
the sift select button turns ON when the front axle has
mode shift is any shift between 2H, 4HSand AUTO.
engaged. The shift select button will blink while the
front axle is engaging. This is a normal condition. The Auto Transfer Case (ATC) Control Module
The shifting of the transfer case is performed will permit a range shift only if the following conditions
by a motor/encoder that receives drive signals from are met within 30 seconds of the request:
the transfer case control module (TCGM). When • Engine running
the driver selects one of the transfer case shift select ® Transmission in Neutral
buttons, request signals are sent to the TCCM. If • Vehicle speed below 3 mph
the correct input signals exists, the TCCM will send
drive voltages to the motor/encoder. The • Proper Motor/Encoder signal present t
motor/encoder will position the transfer case to the A range shift is a shift between high range (2H, 4H,
ordered shift position. and AUTO) and low range (4L).
The Auto Transfer Case (ATC) Control Module will
Transfer Case System Description permit a range shift into or out of Neutral only if
(Automatic 4WD) the following conditions are met:
The two speed Auto transfer case system utilizes a « Ignition ON
part time front axle. The system allows the driver Transmission in neutral
to select the transfer case position with a touch of a
button. The following positions can be selected: • Vehicle speed at zero
4-wheel drive high range (4H), All Wheel Drive Autom atic 4W D Diagnostic Aids
(AUTO), 2 Wheel Drive high range (2H), Neutral (N), A Scan Tool reads and displays the following
and 4-Wheel Drive low range (4L). information:
The Auto Transfer Case (ATC) Control Module
• Diagnostic Trouble code(s)
controls all the shifting action of the transfer case
based on input from the driver as well as information ® Code status bit (are codes set or not)
from the Vehicle Control Module (VCM) /Powertrain • Transfer case lock status
Control Module (PCM).
• Lamp in the switch/lamp assembly
4WD (4H or 4L) mode: This is accomplished by
engaging the front axle, applying PWM to an electric • Motor/Encoder gear position
motor to apply maximum torque, (fully compressing the ® Ignition (3) voltage
transfer case clutch plates) to the front axle, then • Front propshaft speed sensor (KPH)
removing the ground on circuit 1569, thus locking the
motor in position and stop the PWM to the motor. ® Front axle switch (open/closed)
AUTO mode: When in this mode of operation, • Front axle requested position
the system should engage the front axle, then it (engaged/disengaged)
monitors the front and rear propshaft speeds for any • Rear propshaft speed sensor (KPH)
speed differences. When the system senses rear ® Mode switch position request
wheel slip, a difference of propshaft speed between
front and rear, the Auto Transfer Case (ATC) Control • Park switch (open/closed)
Module will use pulse width modulation (PWM) to ® 4WD (Adapt) Mode Auto bit
drive an electric motor. This motor transfers only the ® Current Mode corrective action PWM
required torque to the front wheels to gain additional
traction on slippery surfaces up to 75 mph. There is no ® Average and highest PWM applied during last slip
torque applied to the front wheels until the module recovery event
senses rear wheel slip. ® Throttle anticipation mode
 • Average and highest PWM applied during last Range Shifts
Throttle anticipation corrective action event
1. The range shifts are the shifts between the HI and
• Difference between front and rear propshaft RPM the LO ranges.
• Adapt event counter • 2HI to 4LO
• Throttle position sensor percentage • 4HI to 4LO
Scan Tool • 4LO to 4H I
A Scan Tool can actuate (turn on/off or change • 4LO to 2HI
modes) of the following: 2. A range shift can only be made with the automatic
• Clear Auto Transfer Case (ATC) DTCs transmission in neutral or with the manual
• Service 4WD lamp (tell tail) transmission clutch fully depressed. The shift
occurs when the vehicle speed is below three
• Transfer Case Lock
miles per hour.
• A ll lamps in switch assembly (4WD, 2H, 4H, 4L,
Whenever a shift into 4LO is initiated, the 4LO
and Neutral)
shift select button blinks. The 4LO shift select
• Front Axle button will continue to blink until the shift is
• Request 4W D (Adapt) Mode completed mechanically or until 30 seconds
• Request 2 H Mode elapses. The 4LO shift select button must be on
and not blinking prior to shifting the transmission
• Request 4H Mode into gear or releasing the clutch pedal.
• Request 4L Mode If a range shift is initiated when the transmission is
• Request Neutral engaged or the vehicle speed is above 3 mph, the 4LO
• Drive ATC Motor to various position. 50% PWM shift select button will blink for 30 seconds and no
max with 5 second time out with 10 second range shift actually occurs, the TCCM will default and
wait before re-activating position the transfer case into 4HI.

Mode Shifts Transfer Case C o ntrol Module Description

The mode shifts are shifts from 2HI to 4HI and 4HI to 1. The TCCM performs the following functions:
2HI. A mode shift can be accomplished in any • Receives input signals
gear position and at any vehicle speed. If the system • Processes the signal information
is in 2HI, the driver can shift into 4HI merely by
pressing the 4HI shift select button. The 4HI button • Develops output signals
will blink status whenever a 2H I or 4HI shift is initiated • Sends the output signal in order to control the
and will continue to blink until the TCCM completes shifting of the transfer case
the shift. After the shift into 4HI is accomplished, 2. The TCCM receives input signa ls from the
the 4HI status lamp remains lit to indicate that following sources:
the system is in 4HI.
• The transfer case shift select buttons
There is a difference between when the TCCM sends
• The NSBU switch on the vehicles with
voltage signals in order to engage a four wheel
automatic transmissions
drive shift and when the vehicle is truly in four wheel
drive. The transfer case can be shifted into 4HI • The clutch position switch on the vehicles with
and the front axle may not be engaged. manual transmissions
The driver can shift from 4HI back to 2HI by pressing • The vehicle sped sensor calibrator module
the 2HI shift select button. The 2HI shift select • The encoder/motor range and the mode
button blinks until the shift to 2HI is complete. The 2H I feedback signals
shift select button will remain on once the shift is • The diagnostic enable
mechanically complete.
• The front axle mechanical status signal
3. In order to ensure the electronic shift system is
operating properly, the transfer case control
module (TCCM) continually performs diagnostics
checks on itself and other parts of the electronic
shift system when the ignition switch is in the run
position. The following are different types of
system checks that the TCCM continually
performs.
R A M /R O M C h e c k Motor and Relay Voltage Checks
The TCCM compares the current internal operating Whenever the electric-shift motor is turned ON or
program with a stored operating program. This OFF the motor and the electrical circuits are tested
comparison allows the TCCM in order to evaluate if both in the de-energized and energized condition. If
the TCCM’s RAM and ROM are operating properly. one or both voltage relays fail to detect the proper
Should the TCCM detect a problem with the internal voltage after energizing or de-energized and
operating program, a diagnostic trouble code (DTC) of energized condition. If one or both of the voltage
4 is stored indicating the TCCM memory is damaged. relays fail to detect the proper voltage after energizing
Replace the TCCM. Refer to Transfer Case Control or de-energizing, the shift is aborted by the TCCM
Module Description. and a DTC of 3 is stored in order to indicate a faulty
TCCM motor circuit.
Data Memory Retention Check If one or both relays fail to detect the proper voltage
The TCCM checks the stored diagnostic trouble code after de-energizing, both relays are turned ON by
memory to see if the memory has changed since the TCCM, (even with the ignition switch positioned
the ignition switch was last positioned to OFF. This self OFF) in order to prevent the motor from running. The
test checks in order to see if the RAM standby TCCM then stores a DTC of 3 in order to indicate
power supply has been interrupted. If the TCCM a faulty TCCM motor circuit. All of the status lamps
detects a RAM standby power supply interruption, (the blink three times, stop, and repeat the blinking
loss of stored diagnostic trouble code) the TCCM continuously in order to alert the driver that the
stores a DTC of 1 indicating RAM standby power electronic shift system requires immediate repair. The
failure. battery will drain when this condition occurs,
regardless of the ignition switch position.
This condition occurs when the TCCM is disconnected
from the wiring harness or battery power is removed.
The DTC of 1 automatically clears from the TCCM
Motor/Encoder Circuit Operation
after cycling the ignition switch ON and OFF five times. The TCCM operates the motor/encoder in one
direction by energizing one relay while the second
Encoder Signal Check relay is de-energized. The TCCM operates the motor
in the reverse direction by energizing the second
The TCCM checks the encoder signal in order to relay while the first relay is de-energized. The encoder
verify that the transfer case is in either 2HI, part of the motor/encoder sends shift positioning
4HI, or 4LO. signals to the TCCM.
The motor/encoder converts a shaft position,
Encoder Switch Monitor Check representing a mode of range selection, into electrical
While the transfer case shifts, the encoder within the signals for use by the TCCM. By interpreting the
electric-shift motor is monitored for the proper four channels (P, A, B, C) of the encoder, the transfer
operating sequence. If during a shift, the encoder case control module can detect what position the
changes to an incorrect position, an error counter in transfer case is in 2HI, 4HI, 4LO, or in transition
the TCCM starts to count the number of times between any of the two.
the encoder fails. If the encoder fails eight times, the The four hall effect sensors of the motor/encoder are
TCCM produces a DTC of 2 indicating an Encoder used for channels (A, B, C, and P). These sensors
Fault. When this happens, the TCCM outputs a signal provide a path to ground when a magnet passes over
in order to default the rail shift pattern in the encoder them. A rotating magnetic ring causes the hall
in order to allow for only shifts into 2HI and 4LO. effect sensors voltage to drop from 5 to 0 volts. The
In order to protect against transient, random encoder TCCM detects the voltage of all the channels and
faults caused by vibration, contamination, electrical interprets the current transfer case shift position.
noise, etc., the error counter reduces the count by one
each time a good encoder value is detected. The Special Tools and Equipment
encoder must fail 25 percent of the time for the TCCM
to store a DTC of 2 and indicate a damaged encoder. Illustration Tool Number/Description

J 29162
Output Shaft Seal Instal ler

404841
Driveline/Axle ______ Transfer Case - NVG 246-NP8 (Two Speed Automatic) 4-237

Transfer Case - NVG 246-NP8 (Two Speed Automatic)

Specifications
Fastener Tightening Specifications i'Auto Transfer Case) ................
Specification
Application Metric English
Motor/Encoder Bolts 25 18 ibft
Transfer Case Control Module Screws 8 71 Ib in

Approximate Fluid Capacities

Application Liters Gallons Quarts
NV261 Transfer Case — Use Dexron® III Oil GM 2.2 2.3
P/N 12346143

Scan Tool Data List Use the Transfer Case Scan Tool Data List only after
the following is determined:
The scan tool provides the following capabilities:
• Transfer Case Diagnostic System Check is
• Displays the data list.
completed.
• Displays current and history trouble codes.
• No Diagnostic Trouble Codes (DTCs) are set.
• Clear the diagnostic trouble codes after a repair is
• Transfer Case Diagnostics indicates the system is
completed.
functioning properly.
Make sure the scan tool contains the latest diagnostic
Scan tool values from a properly operating system
information before attempting to communicate with
may be used for comparison with the automatic
the transfer case shift control module. To use the scan
transfer case system you are diagnosing. The Transfer
tool, connect it to the Data Link Connector (DLC)
Case Scan Tool Data List represents values recorded
and turn the ignition switch to the RUN position. The
under the following conditions:
scan tool reads the Class 2 serial data sent from
the transfer case shift control module connector C 1 • Engine is at idle
terminal E9 to the DLC terminal 2. • Closed throttle
The Transfer Case Scan Tool Data List contains all • Gear is in PARK or NEUTRAL
the ATC related parameters that are available on • Accessories are OFF
the scan tool. The list is arranged in the order as they
appear on the scan tool. Important: Make sure the scan tool that you are using
is functioning properly. Use of a malfunctioning scan
tool can result in misdiagnosis and unnecessary
parts replacement.
Only the parameters listed below are referenced in
this service manual for use in diagnosis. If all values
are within the typical range described below, refer
to Intermittents and Poor Connections for diagnosis.
 Scan Tool Data List
Scan Tool Parameter Units Displayed Typical Data Value
Engine is at Idle, Upper Radiator Hose is Hot, Closed Throttle, Gear is in PARK or NEUTRAL, Closed Loop, and
Accessories are OFF
TP Angle % 0
Front Propshaft Speed rpm 0
Rear Propshaft Speed rpm 0
ATC Slip Speed rpm 0
Slip Adapt Mode Enabled/Disabled Disabled
Slip Adapt PWM % DC 0
Last Adapt Highest PWM % DC Varies
Ignition 3 Volts Battery Positive Voltage
Encoder Circuit P On/Off On
Encoder Circuit A On/Off Off
Encoder Circuit B On/Off On
Encoder Circuit C On/Off Off
2WD / 4WD High / 4WD Low /
Commanded Mode Indicator Auto 4WD Varies
2WD / 4WD High / 4WD Low /
Encoder Gear Position Varies
Auto 4WD
Mode Switch Selector On/Off Off
2WD High Indicator Light On/Off Off
Auto 4WD Indicator Light On/Off On
4WD High Indicator Light On/Off Un-
4WD Low Indicator Light On/Off Off
Neutral Indicator Light On/Off Off
Service 4WD Lamp On/Off Off
4WD Lamp Open Yes/No No
4WD Lamp Shorted Yes/No No
Transfer Case Lock Enabled/Disabled Enabled
Front Axle Switch Locked/Unlocked Locked
Front Axle Switch Requested Yes/No Yes
Park Switch Closed/Open Closed
Software ID Number Varies
GM Part Number Number Varies
Scan Tool Data Definitions Encoder Gear Position: The scan tool displays a
range of Auto 4W D to 4W D Low. This parameter
The ATC Scan Tool Data Definitions contain a brief
indicates the actual transfer case sector shaft position
description of all ATC related parameters available on
as sensed by the encoder.
the scan tool. The list is in the order it appears on
the scan tool. Mode Switch Selected: The scan tool displays On
or Off. This parameter indicates the ATC mode
TP (Throttle Position) Angle: The scan tool switch button currently depressed by the driver.
displays a range of 0 -1 0 0 %. The TP Angle is
computed by the PCM from the TP sensor voltage. 2WD High Indicator Light: The scan tool displays
The TP Angle should read 0 percent at idle and On or Off. This parameter indicates if the 2WD
100 percent at Wide-Open Throttle (WOT). High Indicator Light Is being commanded by the
transfer case shift control module.
Front Propshaft Speed: The scan tool displays a
range of 0 -8 1 9 2 RPM. This parameter indicates Auto 4WD Indicator Light: The scan tool displays
the rotational speed of the front propshaft. On or Off. This parameter indicates if the Auto
4WD Indicator Light is being commanded by the
Rear Propshaft Speed: The scan tool displays a
transfer case shift control module.
range of 0 -8 19 2 RPM. This parameter indicates
the rotational speed of the rear propshaft. 4WD High Indicator Light: The scan tool displays
On or Off. This parameter indicates if the 4WD
ATC Slip Speed: The scan tool displays a range of High Indicator Light is being commanded by the
0 -8 19 2 RPM. This parameter indicates the RPM
transfer case shift control module.
difference between the front and rear propshafts.
4WD Low Indicator Light: The scan tool displays
Slip Adapt Mode: The scan tool displays Enabled
On or Off. This parameter indicates if the 4WD
or Disabled. This parameter indicates if the transfer
Low Indicator Light is being commanded by the
case shift control module is currently attempting
transfer case shift control module.
to prevent front to rear propshaft slip.
Neutral Indicator Light: The scan tool displays On
Slip Adapt PWM: The scan tool displays a range of
or Off. This parameter indicates if the Neutral
0 -1 0 0 %. This parameter indicates the duty cycle
Indicator Light is being commanded by the transfer
applied to the ATC motor.
case shift control module.
Last Adapt Highest PWM: The scan tool displays a Service 4WD Lamp: The scan tool displays On or
range of 0 -1 0 0 %. This parameter indicates the
Off. This parameter indicates if the SERVICE indicator
highest duty cycle applied to the ATC motor during the
(AW D/4W D) Lamp is being commanded by the
last slip event.
transfer case shift control module.
Ignition 3: The scan tool displays a range of 4WD Lamp Open: The scan tool displays Yes or
0 -2 5 .5 volts. This parameter indicates the voltage
No. This parameter indicates if the 4W D Lamp circuit is
measured by the transfer case shift control module at
open or shorted to ground, when a Yes is displayed.
its ignition feed.
4WD Lamp Shorted: The scan tool displays
Encoder Circuit P: The scan tool displays On or
Yes or No. This parameter indicates if the 4WD Lamp
Off. This parameter indicates whether transfer
circuit is shorted to voltage or a loss of driver
case shift control module Is sensing voltage on the
ground, when a Yes is displayed.
Encoder Circuit P (On =<1 Volt, Off=3 Volts).
Transfer Case Lock: The scan tool displays
Encoder Circuit A: The scan tool displays On or
Enabled or Disabled. This parameter indicates if the
Off. This parameter indicates whether transfer
transfer case shift control module is commanding
case shift control module is sensing voltage on the
the transfer case motor brake On.
Encoder Circuit A (On=<1 Volt, Off=3 Volts).
Front Axle Switch: The scan tool displays Locked
Encoder Circuit B: The scan tool displays On or or Unlocked. This parameter indicates the feedback
Off. This parameter indicates whether transfer
states of the front axle switch.
case shift control module is sensing voltage on the
Encoder Circuit B (On=<1 Volt, Off=3 Volts). Front Axle Switch Requested: The scan tool
displays Yes or No. This parameter indicates if the
Encoder Circuit C: The scan tool displays On or front axle switch has been requested by the transfer
Off. This parameter indicates whether transfer
case shift control module.
case shift control module is sensing voltage on the
Encoder Circuit C (On =<1 Volt, Off=3 Volts). Park Switch: The scan tool displays Open or
Closed. This parameter indicates the feedback states
Commanded Mode Indicator: The scan tool
of the Park/Neutral Switch.
displays a range of Auto 4W D to 4WD Low. This
parameter indicates the current mode in which ATC is Software ID: The scan tool displays a four-digit
operating. number. This parameter indicates the transfer
case shift control module calibration version number.
GM Part Number: The scan tool displays an
eight-digit number. This parameter indicates the
transfer case shift control module GM software
number.
S c h e m a t ic a n d R o u t in g D ia g r a m s

Transfer Case Control Schematic References

Reference on Schematic Section Number - Subsection Name
Data Link Controls Cell - 50 8 - Data Link Communications
Exterior Lighting Cell -110 8 - Lighting Systems
Ground Distribution Cell - 14 8 - Wiring Systems
Power Distribution Cell - 10 8 - Wiring Systems

Transfer Case Control Schematic Icons

Icon Icon Definition
Refer to ESD Notice in Cautions and Notices

J i 'A
19384

Refer to OBD II Symbol Description Notice in Cautions and Notices

/ 9 bd9 k
19385
 Driveline/Axle
[Hot At All Times 1

_____________________________________________________________________________
1640
C2
¥ 7 ;'1Automatic
•Transfer
1Case
Electronics T-Case 1Control
Ground Ground Lock I Module

.. JgL v- — — — — --— -- — \/-— — — --- vx* — --------------- — — -vr — — — — — — — — « - — — — — — ~y. — — — — — - - — -j A

E16 Cl E15 C F13'fESl r EcT E7" r - ""E6" r F12"
1 3 BLK 150 0.5 0.5 0.5
BLK/WHT 451 BRN/ 1555 YEL/ 1558 BLK/
3 BLK 1552
Ground 0.5 WHT 0.5 BLK WHT 1554
S2151 Distribution - f S204 3 RED LT DK 0.5 0.8 ORN 1640
Cell 14
GRN/ 431 RED/ 1556 0.8
1 BLU/ 1557 TAN 1569
BLK/WHT 451 BLK WHT WHT
----- ^ ^ ------^ ^ ----- ^ ^ ------ ----- 3^.------S -------- ^ P100
{Diesel) K i Q200 3 BLK 150 C131 c ,s E J
/\ G t\ H *> * F * C132 A C C131
(Gas) F 1 t
0.5 0.5 0.8
1
'^P100 3 BLK 1552 BRN/ 1555 YEL/ 1558 0.5 TAN 1569 0.8 ORN 1640
0.5 WHT 0.5 BLK ■ BLK/
BLK/WHT 451 Ground 3 RED 1553 LT DK 0.5 WHT 1554 D. C C2 .
Distribution
Cell 14 GRN/ 431 BLU/ 1557 RED/ 1556 0.8
/ WHT 0.8 ORN 1640
BLK WHT ^ TAN 1569
sioa# Cl E F, £ C A^ Cl
1
1 BLK/WHT 451 A G200 PWR f P ' A1t b \ f” . " GND Automatic
BLK/WHT 451 Batt Transfer
Encoder
\ Case
AGIOS G104 Shift Motor Logic # —H-Brake
(Gas
Engines)
(Gas And
Diesel t U i ’ r Control
Engines)

183198
 Headlamp And
r — — ■ 1 1Panel Dimmer ■§v$tchJq.Pait Qr,Head
I Power. 4 1 1Switch - - , IP
, Distribution J I Power 4 -
ILLUM Fuse
0.8 NT 1Distribution
Ceil 10
E3
Fuse 14 g |0 c k
PPL/WHT 1 1382 r 04 10 A I
i I
► --OS216 _ » M J

1382
Fuse Block
Details
Cell 11
0.55QRY 8
i------------------------ ^
S217 0
0,35 GRY 8
C2 H C1
0
X
(D <D
■HW- T u p
-vW - Automatic
■-W - Transfer
Case
(D <D <D W Select
________
J s----- i ___ —— -------------'H___ —_____ ’it —j Switch
------- , --------- - ---------- -y.
V s
C1 C2 F1 El D C ~~~~ g Y c i
0.35 B 0.35
LT BLU 1693 0.35 0.5 BLK 150
1560 LTGRN/ PPL/ 1565
0.35 BLK 1563 U.uO
0 35 Ground
0.35 TAN/ 1586 WHT 3 2 1 8 1 1 --^ Distribution
LT GRN/ 431 2 BLK 150 Cell 14
PNK 1561 BLK j
F2J ■ __ FI ^01 S204
F16l F14 E3 _ _ _ _ _ E4 V ----- ..---
.F3I.A,___— __ ---- j
" T ”" T " T f " " " 1 f T "" 1 Automatic
Signal +8VDC Neutral AWD 2H Lamp 4H Lamp 4L Lamp Transfer Case
Reg Lamp Lamp Control Module
3 BLK 150
• G200
183183
C o m p o n e n t L o c a to r

Transfer Case Control Components

Name Location Locator View Connector End View
Brake/Transmission Standard Wheel/Column Standard Wheel/Column
On the left side of the IP, to the right of Component Views in Connector End Views in
Shift Interlock (BTSI) the steering column, under the support
bracket Steering Wheel and Steering Wheel and
Solenoid
Column Column
Lighting Systems Lighting Systems
Headlamp and Panel
Dimmer Switch Lower Left side of the IP Component Views in Connector End Views in
Lighting Systems Lighting Systems
Instrument Cluster Instrument Cluster
On the upper left end of the IP, above the Component Views in Connector End Views in
Instrument Cluster steering column Instrument Panel and Instrument Panel and
Console Console
Power and Grounding Power and Grounding
IP Fuse Block To the left of the IP, near the left front Component Views in
door jamb switch Connector End Views in
Wiring Systems Wiring Systems
Automatic Transmission
Electronic Component
AT Internal Connector
Views (Internal) in
End Views in Automatic
Park/Neutral Position Automatic Transmssions- Transmission- 4L60-E or
At LH center of Transmission 4L60-E or Automatic
(PNP) Switch AT Internal Connector
Transmission Electronic
Component Views End Views in Automatic
(Internal) in Automatic Transmissions- 4L80-E
Transmissions- 4L80-E
Engine Controls PCM Connector End
Powertrain Control Under RH end of IP, above Blower Motor, Component Views in Views in PCM Connector
Module (PCM) (Diesel) behind IP Compartment Box
Engine Controls End Views
Hydraulic Brakes Hydraulic Brakes
Stoplamp Switch On the top of the brake pedal Component Views in Connector End Views in
Lighting Systems Lighting Systems
Tranfer Case Transfer Case Control Transfer Case Control
LH Center of Transfer Case
Encoder Motor Component Views Connector End Views
Transfer Case Control
Under IP, near the convience center Transfer Case Control Transfer Case Control
Module (TCCM) Component Views Connector End Views
(Selectable 4WD)
Transfer Case Select Center of IP, RH of steering column Transfer Case Control Transfer Case Control
Switch shift lever Component Views Connector End Views
Engine Controls VCM Connector End
Component Views(4.3L), Views(4.3L), VCM
Engine Controls Connector End Views
Vehicle Control Module
Engine Compartment, near EBCM Component Views (5.0, (5.0, 5.7L), or VCM
(VCM) (Gas)
5.7L), or Engine Controls Connector End Views
Component Views (7.4L) (7.4L) in VCM Connector
in Engine Controls. End Views
Part of the engine harness to IP harness, Inline Harness Connector
C100 in the left rear side of the engine Harness Routing Views in End Views in Wiring
Wiring Systems
compartment, at the bulkhead Systems
Part of the engine harness to front axle Inline Harness Connector
Harness Routing Views in
C120 actuator, in the rear of the engine, near End Views in Wiring
Wiring Systems Systems
the transmission
Inline Harness Connector
IP harness, Inline to Active Transfer Case Harness Routing Views in
C131 Control harness End Views in Wiring
Wiring Systems Systems
Inline Harness Connector
C132 IP harness, Inline to Active Transfer Case Harness Routing Views in End Views in Wiring
Control harness Wiring Systems Systems
Behind the right side of the IP, near the Inline Harness Connector
C200 Harness Routing Views in End Views in Wiring
heater motor, in foam wrap Wiring Systems Systems
 Transfer Case Control Com ponents (cont’d)
Name Location Locator View Connector End View
Harness Routing Views in Inline Harness Connector
C227 (Stoplamp Switch) IP harness, Inline to the Stoplamp Switch Wiring Systems End Views in Wiring
Systems
Part of the IP harness to steering column
Harness Routing Views in Inline Harness Connector
C266 harness, to the left side of the steering End Views in Wiring
Wiring Systems
column, near the bulkhead Systems
Power and Grounding Power and Grounding
On the right front side of the engine, near Component Views in
G103 (Gas) the thermostat housing Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
G104 (5.0L/5.7L) Backside of the right cylinder head Component Views in Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
G104 (6.5L) Top rear of the right cylinder head Component Views in Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
Backside of the engine block, below the Component Views in
G104 (7.4L) Connector End Views in
right cylinder head Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
G105 (Gas) On the right front side of the engine block Component Views in Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
Right Rear of the cylinder head, cylinder Component Views in
G105 (Diesel) #7 intake bolt Connector End Views in
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
Behind the left side of the IP, below the Component Views in
G200 fuse block, on the tie bar Connector End Views in
Wiring Systems Wiring Systems
In the left rear side of the engine Harness Routing Views in Inline Harness Connector
P100 compartment, at the bulkhead, End Views in Wiring
Wiring Systems
above C100 Systems

In the right rear side of the engine Harness Routing Views in Inline Harness Connector
P101 compartment, at the bulkhead Wiring Systems End Views in Wiring
Systems
Engine harness, approx. 8 cm (3 in) from
S103 (5.0L, 5.7L) EGR valve breakout, toward taillamp — — .

harness breakout
Engine harness, approx. 12 cm (4.7 in)
S103 (6.5L) from starter solenoid breakout, towards the — —
Underhood Lamp harness breakout
Engine harness, approx. 8 cm (3 in) from
S103 (7.4L - A/T) the EGR Valve harness breakout, towards —
the Ignition Coil harness breakout
Engine Harness, approx. 4 cm (1.5 in)
S103 (7.4L - M/T) from the Fuel Injector harness breakout, —
towards the Taillamp harness breakout
engine harness, approx. 5 cm (2 in) from
S147 (Gas) EGR valve breakout, toward taillamp — ' —
harness breakout
Engine harness, approx. 4 cm (1.5 in) from
S147 (Diesel) starter motor solenoid breakout —
Engine harness, approx. 17 cm (6.5 in)
S162 (5.0L, 5.7L ) from starter solenoid breakout, toward LH — —
oxygen sensor breakout
Engine harness, approx. 15 cm (6 in) from
S162 (7.4L) RH bank oxygen sensor breakout, toward — —
starter solenoid breakout
S204 IP harness, approx. 10 cm (4 in) from
C100, towards Data Link Connector (DLC) — —
 Transfer Case Control Components (cont’d)
Name Location Locator View Connector End View
IP harness, approx. 4 cm (1.5 in) from
S213 steering column harness breakout, towards — —
the DLC
IP harness, approx. 8 cm (3 in) from
S215 instrument cluster breakout, toward radio — —
connectors breakout
IP harness, approx, 12 cm (4.5 in) from
S216 (Diesel and instrument cluster breakout, toward radio — —
Uplevel) connectors breakout
IP harness, approx. 16 cm (6 in) from
S216 (Gas, all except instrument cluster breakout, toward radio —
uplevel —
connectors breakout
IP harness, approx. 16 cm (6 in) from
S217 instrument cluster harness breakout, — —
toward radio connectors breakout
IP harness, approx. 16 cm (6 in) from
S218 inflatable restraint switch breakout —
IP harness, approx. 4 cm (1.5 in) from
S235 steering column harness breakout, C100 —
IP harness, approx. 10 cm (4 in) into
S236 steering column harness towards the — —
Steering Column
IP harness, approx. 5 cm (2 in) from DLC —
S280 —
breakout
Selectable 4WD harness, approx.
S302 10 cm (4 in) from the Tranfer Case Relay — —
breakout, toward the Front Axle Switch
Transfer Case Control Component Views
Automatic 4WD Support Wiring

429318

Legend
(1) Automatic Transfer Case Control Module (4) Convenience Center
(2 ) IP Harness (5) IP Reinforcement Brace
(3) Daytime Running Lights Control (DRL)
Module
 Transfer Case Switch (M30)

183946

Legend

(1) Heated Oxygen Sensor Connectors (3) Transfer Case Switch

(2) Vehicle Speed Sensor (4) Transfer Case
 Transfer Case Select Switch

183948

Legend

(1) Radio Connector (4) Rear Fan Switch

(2) Rear Wiper Switch (5) Electric Shift Transfer Case Switch or Fog
(3) Cargo Lamp Switch Lamp Switch
 Transfer Case Relay

183902

Legend

(1) Transfer Case Re lay

(2) Front Axle Actuator
 C224 and C225

Legend

(1) Cruise Control Module (7) Rear Lamp Harness

(2) Pass Through Grommet P100 (8) Engine Harness
(3) Connector C100 (9) Windshield Wiper Motor
(4) Connector C110 (10) Connector C225
(5) Connector C104 (11) Connector C224
(6) Connector C111
 P100

Legend

(1) Connector C102 (6) Connector C101

(2) LH Front Headlamp Connectors (Composite) (7) Ground G113
(3) Park And Turn Lamp LH Front (8) Connector C100
(4) LH Fog Lamp Connector (9) Pass Through Grommet P100
(5) Horn
 6.5L Diesel Engine, RH Side

172401

Legend

(1) Engine Harness (4) Grounds G150 And G105

(2) Generator Connector (5) Ground G104
(3) Turbo
Transfer Case Control Connector End Transfer Case Shift Control Module C1
Views (cont’d)

Transfer Case Shift Control Module C1 IEl E18

A - , r fr .........

r
I l l I

u1 u ....... 1 1..i 91 / .
..~ ~ /
FI F16

73221

Connector Part • 12052107

Information • ASM 16F 100 Series (BLK)

Connector Part • 12052107 Circuit

Wire Color
Information Pin No. Function
• ASM 16F 100 Series (BLK)
4 ’LO’ Indicator Lamp
Circuit Ft PPL/WHT 1565
Wire Color Output
Pin No. Function
4 ’HI’ Indicator Lamp
TAN
Transfer Case Lock F2 TAN/BLK 1566
Output
E1 1569
Solenoid Output
Neutral Indicator Lamp
LT BLU/ Service 4WD/AWD F3 BRN 1560
E2 1567 Output
BLK Indicator Lamp Output
Front Axle Actuator
AWD Indicator Lamp F4 GRY/BLK 1570
E3 PNK 1561 Output
Output
F5 LT BLU 2221 Rear Propshaft Signal
LT GRN/ 2 ’HI’ Indicator Lamp
E4 1563
BLK Output F6 DK GRN 2222 Rear Propshaft Return
Transfer Case Position F7 GRY/BLK 1694 4WD Switch Signal - Low
E5 BRN/WHT 1555 Switch Encoder Signal -
fs - Not Used
Channel P — —
ii
Transfer Case Position
T ransfer Case Encoder
E6 RED/WHT 1556 Switch Encoder Signal - F12 BLK/WHT 1554
Channel C Signal Return

Transfer Case Position LT GRN/ Reference Voltage Feed -

F13 431
Switch Encoder Signal - BLK 8 Volt Reference
E7 YEL/BLK 1558
Channel B LT Reference Voltage Feed -
F14 431
Transfer Case Position GRN/BLK 8 Volt Reference
DK BLU/
E8 1557 Switch Encoder Signal - Transmission Mounted
WHT
Channel A F15 LTGRN 275 Neutral Safety Switch
Output - Park
Serial Data Signal - Class
E9 PPL 1807 B - 10400 BAUD - LT BLU/ 4WD Switch Signal
F16 1693
Primary BLK
Fuse Output - Ignition 3 -
E10 BRN 241
Type III Fuse
E11 Not Used
Front Propshaft Sensor
E12 YEL 400
Signal
Front Propshaft Sensor
E13 PPL 401
Return
4WD Front Wheel Lock
E14 BLK/WHT 1695 Telltale Feed
E15 Not Used
E16 BLK/WHT 451 ECM Ground
 Transfer Case Select Switch Connector C1
Transfer Case Shift Control Module (cont’d)
Connector C2

^ ^ ^ ^
c2] cSbcS cSb
£=L
62463

Connector Part • 12064766

Connector Part 12052856 Information • CONN 8F M/P 150 (BLK)
Information CONN 4F M/P 280 (BLK)
Wire Color Circuit
Circuit Pin No. Function
Pin Wire Color No, Function LTGRN/ 2 ’HI’ Indicator Lamp
1563
Transfer Case Motor BLK Output
BLK 1552
Feed - CW
PNK 4WD Indicator Lamp
1561
Transfer Case Motor Output
RED 1553
Feed - CCW G BLK 150 Ground
BLK 150 Ground GRY IP Lamp Feed
Fuse Output - Battery ■
ORN 1640
Type III Fuse_____ _
Transfer Case Select Switch, Connector C2

Transfer Case Select Switch Connector C1

I
^
E£P ^ ^ — 3

[S b c S b c£b
a x ___ -___________ i :
Connector Part 12045813
Information CONN-4F M/P 150 (BLK)
Connector Part • 12064766
Information Circuit
• CONN 8F M/P 150 (BLK) Pin Wire Color Function
No.
Circuit Not Used
Wire Color Function
Pin No.
PPL/WHT 1382 LED Dimming Signal
LT GRN/ Reference Voltage Feed ■
431
BLK 8 Volt Reference Use Output - Ignition 3 ■
BRN 241
LT BLU/ 4WD Switch Signal Type III Fuse
1693
BLK Neutral Indicator Lamp
BRN 1560
4 ’LO5Indicator Lamp Output ________
PPL/WHT 1565
Output
4 ’HP Indicator Lamp
TAN/BLK 1566
Output
Transfer Case Encoder Motor Connector C1 Transfer Case Encoder Motor Connector C2
(cont’d)

12191399
Connector Part
Information 4F Metri-Pack 280 Series, Connector Part 12052848
Flexiock, Sealed (BLK) Information 6 Way F Metri-Pack
Circuit 150 Series, Sealed (BLK)
Pin Wire Color No* Function Circuit
Transfer Case Motor Pin Wire Color No- Function
BLK 1552
Feed - Clockwise Transfer Case Position
YEL/BLK 1558
Switch Encoder Signal
Transfer Case
RED 1553 Motor Feed - LT GRN/ Reference Voltage Feed
Counterclockwise 431
BLK - 8 Volt Reference
Fuse Output - Battery ■ Transfer Case Position
ORG 1640
Type III Fuse BRN/WHT 1555
Switch Encoder Signal
Transfer Case Lock
TAN 1569
Solenoid Output Front Axle Actuator

Transfer Case Encoder Motor Connector C2

365944

Connector Part • 12077591

Information • ASM 5F M/P 150 (BLK)
• 12052848 Circuit
Connector Part Wire Color
Information • 6 Way F Metri-Pack Pin No. Function
150 Series, Sealed (BLK)
4WD Front Wheel Lock
Circuit BLK/WHT 1695
Telltale Feed
Pin Wire Color No. Function
Front Axle Actuator
Transfer Case Encoder GRY/BLK 1570
Output
BLK/WHT 1554
Signal Return
Fuse Output - Ignition 3 ■
DK Transfer Case Position BRN 241
Type II Output
1557
BLU/WHT Switch Encoder Signal
Not Used
Transfer Case Position
RED/WHT 1556
Switch Encoder Signal BLK 150 Ground
Prop Shaft Speed Sensor, Front Connector
Prop Shaft Speed Sensor, Rear Connector

Connector Part • 12162194

Information • 2F Metri-Pack 150.2 Series, • 12162194
Connector Part
Sealed (BLK) - Information • 2F Metri-Pack 150.2 Series,
Circuit Sealed (BLK)
Pin Wire Color No, Function Circuit
Vehicle Speed Sensor Pin Wire Color No. Function
YEL 400 Signal Vehicle Speed Sensor
LT BLU 2221
Vehicle Speed Sensor Signal
PPL 401 Return Vehicle Speed Sensor
DKGRN 2222 Return
D ia g n o s t ic I n f o r m a t io n a n d P r o c e d u r e s

Intermittents and Poor Connections T ra n s fe r C a s e G e n e ra l D ia g n o s is

Most intermittents are caused by faulty electrical Diagnostic Trouble Codes
connections or wiring. Some items to check are:
The Transfer Case Diagnostic System Check must
• Poor mating of connector halves, or terminals not always be the starting point of any system diagnosis.
fully seated in the connector body (backed out). The Transfer Case Diagnostic System Check
• Dirt or corrosion on the terminals— The terminals verifies proper SERVICE indicator (AW D/4W D) lamp
must be clean and free of any foreign material operation and checks for ATC diagnostic trouble codes
which could impede proper terminal contact. (DTC) using the scan tool. The following describes
• Damaged connector body, exposing the terminals the difference between current and history DTCs:
to moisture and dirt, as well as not maintaining • Current DTCs - Malfunctions that are presently
proper terminal orientation with the component or being detected. Random access memory
mating connector. (RAM) stores the current DTCs. Turning the
• Improperly formed or damaged terminals— All ignition switch to the OFF position resets current
connector terminals in problem circuits should DTCs and logs the codes in history. The
be checked carefully to ensure good contact presence of a current DTC will cause the transfer
tension. Use a corresponding mating terminal to case shift control module to turn ON the
check for proper tension. SERVICE indicator (AWD/4WD) lamp.
• J 3 5 6 1 6 -A Connector Test Adapter Kit must be • History DTCs - All malfunctions detected since
used whenever a diagnostic procedure requests last clearing of history memory. Electrically
checking or probing a terminal. Using the adapter erasable programmable read only memory
will ensure that no damage to the terminal will (EEPROM) stores the history DTCs. A scan tool
occur, as well as giving an idea of whether contact clear codes command will erase history DTCs.
tension is sufficient. Use of Special Tools
• Poor terminal to wire connection— Some
You should be familiar with the tools in this service
conditions which fall under this description are
category listed under the heading Special Tools. You
poor crimps, poor solder joints, crimping over wire
should know how to measure voltage and resistance.
insulation rather than the wire itself, corrosion
Diagnosis requires proper use of the following tools:
in the wire to terminal contact area, etc.
• The Scan Tool
• Wire insulation which is rubbed through, causing
an intermittent short as the bare area touches • The J 39200 Digital Multimeter
other wiring or parts of the vehicle. • The J 35616-A Connector Test Adapter Kit
• Wiring broken inside the insulation. This condition
could cause a continuity check to show a good T ra n s fe r C a se D ia g n o s tic S y s te m C h e c k
circuit, but if only one or two strands of a These diagnostic procedures will help you to find
multi-strand type wire are intact, resistance could and repair automatic transfer case (ATC) system
be far too high. malfunctions. This service category also contains
To avoid any of the above problems when making information for repairing ATC system malfunctions. For
wiring or terminal repairs, always follow the instructions best results, use the diagnostic tab les, and follow
for wiring and terminal repairs. the sequence listed below:
1. Perform the Transfer Case Diagnostic System
Check. All ATC diagnostics must begin with the
Transfer Case Diagnostic System Check.
The Transfer Case Diagnostic System Check
determines the following:
• Proper SERVICE indicator (AWD/4WD) lamp
operation
• Ability of the transfer case shift control module
to communicate through the data link
connector (DLC)
• Existence of ATC diagnostic trouble
codes (DTC)
2. Refer to the diagnostic table as directed by the Circuit Description
Transfer Case Diagnostic System Check. The The ignition switch supplies Ignition 3 voltage to the
diagnostic tables will help enable you to diagnose transfer case shift control module at connector C1
any ATC system malfunction. Bypassing these terminal E 10 using the 4WD Fuse. When the ignition
procedures may result in the following: switch is first turned to the RUN position, the
transfer case shift control module responds by flashing
• Extended diagnostic time the SERVICE indicator (AWD/4WD) lamp for
• Incorrect diagnosis approximately 2 seconds, then turning it OFF, while
performing tests on the ATC system. The transfer case
• Incorrect parts replacement shift control module will continue to perform tests on
3. Repeat the Transfer Case Diagnostic System the ATC system during a normal drive cycle.
Check after you perform any repair or diagnostic Test Description
procedures. This will verify that you correctly The number(s) below refer to the step number(s) on
performed the repair. This will also ensure that no the diagnostic table.
other malfunctions exist. 2. This test checks for proper operation of the Serial
Data line.
3. This test will identify the stored diagnostic trouble
codes and whether or not they are current or
history.
7. The SERVICE 4W D lamp should turn off after
approximately 2 seconds.

Transfer Case Diagnostic System Check

Step Action Value(s) Yes No
1. Turn the ignition switch to the RUN position.
1 2. Observe the SERVICE indicator (AWD/4WD) lamp on Go to Service
the instrument cluster. Indicator Does
Did the SERVICE indicator (AWD/4WD) lamp turn ON? Go to Step 2 Not Light
1. Turn the ignition to OFF.
2. Connect a Scan Tool to the Data Link Connector
(DLC). Follow the directions in the instruction manual
of the scan tool.
2 — Go to Data Link
3. Turn the ignition switch to the RUN position.
Communications
4. Attempt to communicate with the transfer case shift System Check in
control module. Electrical
Does the scan tool communicate with the module? Go to Step 3 Diagnosis
Request for ATC Diagnostic Trouble Codes (DTCs)
3 display. —■ ■ Go to Diagnostic
Are there any Current DTCs present in the module? Trouble Codes Go to Step 4
4 Are there any History DTCs present? — Go to Step 11 Go to Step 5
1. Set parking brake.
2. Start the vehicle engine.
3. Depress brake pedal and hold.
4. Place transmission in Neutral.
5 —
5. Use the scan tool to monitor Encoder Gear Position
while depressing each of the transfer case select Go to
buttons. Range/Mode
Do all the transfer case select buttons enable the Switch
appropriate mode for the Encoder Gear Position? Go to Step 6 Inoperative
Do all Mode Switch Indicator Lamps light when their Go to Switch
corresponding switch is depressed? Indicator Lamps
6 — Do Not Light
Go to Step 7 One or More
 Transfer Case Diagnostic System Check (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition to OFF.
2. Turn the ignition switch to the RUN position.
7 3. Observe the SERVICE indicator (AWD/4WD) lamp on — Go to Service
the instrument cluster. Indicator Stays
Did the SERVICE indicator (AWD/4WD) lamp turn ON and ON When Key
turn OFF after approximately 2 seconds? Go to Step 8 is ON
Was the vehicle brought in for a performance concern? Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check for 4.3L, A
Powertrain On
8 Board Diagnostic
— (OBD) System
Check for 5.0,
5.7L, and A
Powertrain On
Board Diagnostic
(OBD) System
Check for 6.5L Go to Step 9
1. Take the vehicle on a road test.
2. Attempt to duplicate the customer’s complaint.
9 —
3. After the road test check for ATC DTCs. Go to Diagnostic
Were there any Current ATC DTCs present? Trouble Codes Go to Step 10
Were there any mechanical problems identified on the Go to Transfer
road test? Case Mechanical
10 — System
Diagnosis System OK
1. A History DTC indicates a malfunction has been
repaired (but DTCs were not cleared) or that
malfunction is intermittent.
2. Record any History DTCs set.
11 3. Clear ATC DTCs. —
4. Take vehicle on a road test.
5. Attempt to engage AWD.
6. After the road test check for ATC DTCs. Go to Diagnostic
Were there any ATC DTCs present? Trouble Codes Go to Step 12
Refer to Diagnostic Aids for the recorded History DTC.
12 — —
Are the repairs complete? Go to Step 1
 Diagnostic Trouble Codes
Symptom/DTC Diagnostic Table
DTC B0768 DTC B0768 S e r v i c e Indicator Circuit High
DTC B2725 DTC B2725 ATC Mode Switch Circuit Malfunction
DTC C0300 DTC C0300 Rear S p e e d Sensor Malfunction
DTC C0305 DTC C0305 Front Speed Sensor Malfunction
DTC C0308 DTC C0308 Motor A/B Circuit Low
DTC C0309 D T C C 0 3 0 9 M o t o r A /B C ir c u it H ig h
DTC C0310 DTC C0310 Motor A/B Circuit Open
DTC C0315 DTC C0315 Motor Ground Circuit Open
DTC C0323 DTC C0323 T-Case Lock Circuit Low
DTC C0324 DTC C0324 T-Case Lock Circuit High
DTC C0327 J 0 C0327 Encoder Circuit Malfunction
DTC C0357 DTC C0357 P a r k Switch Circuit High
DTC C0362 DTC C0362 4LO Discrete Output Circuit High \
DTC C0367 DTC C0367 Front Axle Control Circuit High
DTC C0374 DTC C0374 General System Malfunction
....DTC 003769 .............. DTC C0376 F r o n t / R e a r Shaft Speed Mismatch
DTC C0550 D T C C 0 5 5 0 E C U M a lfu n c tio n
DTC C0611 DTC C0611 VIN Information Error
U-Code DTC Refer to the applicable table in Data Link Connector (DLC) in Electrical Diagnosis
 I Hot In ON, Bulb Test And STAHT

I Power
GAUGES
I Distribution
Cell 10
H8
Fuse 4
i 10 A
J7 j

0.8 PNK 39
Fuse Block
Details 1S213
Cell 10
0.35 PNK 39
22
1 1nstrument
i Instrument
Cluster q r 1Cluster
I Cell 81 I
Service
1 ' 4WD I
i I
L I
24

0.35 LT BLU/BLK 1567

E Z IC I
Transfer
!" indicator "I
ump Case Shift
I output I control
■■ “ “ “ J Module

450722

Circuit Description Conditions for Clearing the MIL/DTC

The transfer case shift control module controls the • The transfer case shift control module will clear
SERVCE indicator (AWD/4WD) lamp, located in the DTC if the condition for setting the DTC no
the instrument cluster, by grounding CKT 1567. longer exists.
Voltage to the lamp is supplied via the GAUGE Fuse, • A history DTC will clear after 100 consecutive
CKT 39. The fuse is located in the IP Fuse Block. ignition cycles without a fault present.
Conditions for Setting the DTC • Use a scan tool in order to clear history DTCs.
After the transfer case shift control module commands Test Description
the lamp on, the module senses a voltage greater
The number(s) below refer to the step number(s) on
than 7 V on CKT 1567.
the diagnostic table.
3. This step determines whether circuit 1567 is
shorted to voltage.
6 . Jumping terminal E 2 of the transfer case shift
control module harness connector to ground
should provide a complete path to ground for the
SERVICE indicator (AWD/4WD) lamp. This
step attempts to eliminate the instrument cluster
and wiring from fau lt.
 DTC B0768 Service indicator Circuit High
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect the instrument cluster connector.
2 3. Inspect the instrument cluster connector terminals for —■
damage or corrosion
Are the terminals damaged or corroded? Go to Step 5 Go to Step 3
1. Disconnect the instrument cluster harness conneclor.
2. Disconnect both transfer case shift control module
connectors.
3 3. Connect a J 39200 Digital Multimeter DMM between OV
connector C1 terminal E2 at the transfer case shift
control module harness and ground.
4. Turn the ignition to RUN.
Is the voltage reading greater than the specified voltage? Go to Step 4 Go to Step 6
Repair a short to voltage in CKT 1567. Refer to Wiring
4 Repairs. ■ —■ ' —
Is the repair complete? Go to Step 11
Repair the instrument cluster wire harness connector.
5 Refer to Connector Repairs in Wiring Systems. —
Is the repair complete? Go to Step 11
1. Turn the ignition OFF.
2. Reconnect the instrument cluster.
6 3. Connect a 3 A fused jumper wire from terminal E2 at —
the transfer case shift control module to ground.
4. Turn the ignition to RUN.
Does the SERVICE indicator (AWD/4WD) lamp light? Go to Step 7 Go to Step 8
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
7 (Automatic 4WD). '— ■ — ■
Is the action complete? Go to Step 11
Inspect instrument cluster SERVICE indicator (AWD/4WD)
8 lamp for faulty bulb. ' — ■■
Is the bulb good? Go to Step 11 Go to Step 9
Replace instrument cluster SERVICE indicator
(AWD/4WD) bulb. Refer to Instrument Cluster Lamp
9 Replacement in Instrument Cluster. ■ ■—, —
Is the repair complete? Go to Step 10
Remove instrument cluster for service. Refer to IP Cluster
10 Replacement in Instrument Cluster. — —
Is the repair complete? Go to Step 11
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
11 disconnected ATC components. — ' —
Have all the ATC components been reconnected and
properly mounted? Go to Step 12
Clear all ATC DTCs. Go to Transfer
12 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
DTC B2725 ATC Mode Switch Circuit Malfunction

64.9
1Transfer
Auto 1Case
r -V W - 4WD
715 1Select
,---- 4 HI • Switch
1.82K 1
1
W - 2 HI
1
3.16K
p
---- - 4 LO J
9.Q9K
----yyyi-----------

ATC1

0.35 LT BLU 1693

0.35
LT GRN/BLK 431

Fie
"JTransfer
JCase
Shift
'Control
j Module

A
450729

Circuit Description O nce these conditions have been met, pressing and
holding both the 2HI and 4LO buttons for 10 seconds
The range/mode switch circuit consists of 4 normally
open switches. The transfer case shift control will shift the transfer case into neutral, turning on
module supplies a regulated 8 volt DC to the switch the red neutral indicator lamp.
through CKT 431. The switch has CKT 1693 to return This D TC detects an open, short to ground, or voltage
current to the transfer case shift control module on C K T 431 and C K T 1693, and a faulty switch
through a 9.09 K resistor located inside the switch. assembly.
The transfer case shift control module constantly Conditions for Setting the DTC
monitors this signal voltage to determine the condition
• The system constantly monitors the voltage on
of the mode switch circuit. If no buttons are pressed,
C K T 1693.
and the transfer case shift control module detects
a voltage level outside the possible range (approx. • If the system detects a voltage level outside the
0.5-1.0 volts) for longer than 5 minutes, the transfer possible range produced when no buttons are
case shift control module will set this D TC or if a button depressed, (approx. 0 .5 -1 .0 volts), the DTC
is held down or sticks for a period longer is logged.
than 5 minutes. W hen each of the switches is Action Taken When the DTC Sets
depressed they will complete a circuit through their
• All shifting will be disabled.
own specific resistor. The transfer case shift control
module continuously monitors the switch input to • The S E R V IC E indicator (A W D /4W D ) lamp will be
determine whether the 4Hl, AUTO 4WD, 2HI, and 4LO latched on for the remainder of the current
button selectors are made by the driver. Neutral ignition cycle.
may be obtained if the following conditions are met: Conditions for Clearing the DTC
• T h e engine is running. • The transfer case shift control module will clear
• The automatic transmission is in neutral (or the the D TC if the condition for setting the DTC no
>clutch pedal is depressed on a manual longer exists.
transmission application). • A history DTC will clear after 100 consecutive
• T h e vehicle speed is below 3 MPH. ignition cycles without a fault present.
• T h e transfer case is in the 2HI mode. • History DTCs can be cleared using a scan tool.
Test Description 10. This step determines if circuit 431 is shorted to
The number(s) below refer to the step number(s) on voltage.
the diagnostic table. 14. This step determines if circuit 431 is shorted
3. This step determines if circuit 1693 is shorted to ground.
voltage. 16. This step determines if circuit 431 is open.
6. This step determines if circuit 1693 is open.

DTC B2725 ATC Mode Switch Circuit Malfunction

Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to T r a n s f e r
1 performed? — C a s e D ia g n o s tic
Go to S t e p 2 S y s te m C h e c k

1. Turn the ignition OFF.

2. Disconnect the Selector Mode Switch connectors.
3. Use a J 3 9 2 0 0 Digital Multimeter DMM in order to
2 measure the voltage from the Selector Mode Switch 7-9 V
harness connector C1 terminal A to ground.
4. Turn the ignition On.
Is the voltage within the specified values? Go to S t e p 3 Go to S t e p 9
1. Turn the ignition OFF.
2. Disconnect the transfer case shift control module
harness connectors.
3 3. Turn the ignition to Run. 0V
4. Use a J 3 9 2 0 0 DMM in order to measure the voltage
from transfer case shift control module harness
connector G1 terminal F16 to ground.
Is the voltage greater than the specified value? Go to S t e p 1 1 Go to S t e p 4
Connect a J 3 9 2 0 0 DMM and measure the resistance
between Selector Mode Switch harness connector C1
4 terminal B to ground. OL
Is the resistance measured l ess than the specified value? Go to S t e p 5 Go to S t e p 6
Repair a short to ground in CKT 1693. Refer to W i r i n g
5 R e p a i r s in Wiring Systems. —
Is the repair compl ete? Go to S t e p 1 8
Connect a J 3 9 2 0 0 DMM from Selector Mode Switch
harness connector C1 terminal B to transfer case shift
6 control module harness connector C1 terminal F16 0-5 O
Is the resistance measured within the specified value? Go to S t e p 7 Go to S t e p 8
Replace the Selector Mode Switch. Refer to T r a n s f e r C a s e
7 D r iv e r C o n tr o l S w itc h R e p la c e m e n t ( A u t o m a t ic 4 W D ) . — —
is the action complete? Go to S t e p 1 8
Repair open CKT 1693. Refer to W i r i n g R e p a i r s in Wiring
8 Systems. ' — — .
Are the repairs complete? Go to S t e p 1 8
Was the voltage in Step 2 within the specified value? Greater
9 Go to S t e p 1 4
than 9 V Go to S t e p 1 0
1. Turn the ignition OFF.
2. Disconnect the transfer case shift control module
connectors.
10 3. Connect a J 3 9 2 0 0 DMM between the transfer case 0V
shift control module connector C1 terminal A to
ground.
4. Turn the ignition to RUN,
Is the voltage greater than the specified value? Go to S t e p 1 3 Go to S t e p 1 2
Repair a short to voltage in CKT 1693. Refer to W i r i n g
11 R e p a i r s in Wiring Systems. — ■— .
Is the repair complete? Go to S t e p 1 8
 DTC B2725 ATC Mode Switch Circuit Malfunction (cont’d)
. Step . Action Value(s) Yes No
Replace the transfer case shift control module. Refer to
T r a n s f e r C a s e C o n tr o l M o d u le R e p la c e m e n t
12 (Automatic 4 W D ) . — —
Is the action complete? Go to Step 18
Repair a short to voltage in CKT 431. Refer to Wiring
13 Repairs in Wiring Systems. —■ —
Is the repair complete? Go to Step 18
1. Disconnect the transfer case shift control module
harness connectors.
14 2. Connect a J 39200 DMM and measure the resistance OL
between Selector Mode Switch harness connector C1
terminal A to ground.
Is the resistance measured less than the specified value? Go to Step 15 Go to Step 16
Repair a short to ground in CKT 431. Refer to Wiring
15 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 18
Connect a J 39200 DMM from Selector Mode Switch
harness connector C1 terminal A to transfer case shift
16 control module harness connector C1 terminal F14 0-5 0
Is the resistance measured within the specified value? Go to Step 12 Go to Step 17
Repair open CKT 431. Refer to Wiring Repairs in Wiring
17 Systems. — —
Are the repairs complete? Go to Step 18
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
18 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 19
Clear all ATC DTCs. Go to Transfer
19 Have all the ATC DTCs been cleared? — Case Diagnostic ■—
System Check
DTC C0300 Rear Speed Sensor Malfunction

■'Transfer
'Case
RSSLO RSSHI ■ Shift
I •Control
i. l J Module
F6
0.5 DK GRN A
2221

m m

K C132

0.5 DK GRN 2222

0.5 LT BLU 2221

Rear
Propshaft
Speed
" tr Sensor

450732

Circuit Description Action Taken When the DTC Sets

The rear propshaft speed sensor is a permanent • All shifts to AUTO (Adapt) mode will be disabled.
If the current mode is AUTO, the system will not
magnet (PM) generator. The PM generator produces a
allow any further adaptive events (correct slip).
pulsing AC voltage. The AC voltage level and
• The SERVICE indicator (AWD/4WD) lamp will be
number of pulses increases as speed increases. The latched on for the remainder of the current
module converts the pulsating AC voltage to a ignition cycle.
propshaft RPM which is used for calculations. The
Conditions for Clearing the DTC
propshaft RPM can be displayed with a scan tool. The
module only monitors this input when the vehicle is • The transfer case shift control module will clear
the DTC if the condition for setting the DTC no
in 2H.
longer exists.
This DTC detects an open, short to ground, or faulty • A history DTC will clear after 100 consecutive
sensor. ignition cycles without a fault present.
• History DTCs can be cleared using a scan tool.
Conditions for Setting the DTC
Test Description
The system will log the DTC if the rear propshaft input The number(s) below refer to the step number(s) on
indicates a speed of less than 16 RPM for 30 seconds the diagnostic table.
while all of the following are true: 4. This step determines if the rear speed sensor is
• The transmission is NOT in Park/Neutral. able to generate AC current and indicates that
both the sensor and wiring to the transfer
• The engine is running. case shift control module is good.
• The front axle is engaged. 5. This step measures the internal resistance of the
rear speed sensor and whether or not it is within
• The rear propshaft speed exceeds 512 RPM. acceptable limits.
• The vehicle speed on Class 2 Data bus exceeds 7. This step determines if circuit 2222 has a short to
10 mph. voltage.
 DTC C0300 Rear Speed Sensor Malfunction
Step ction ; Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — ' Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition OFF.

2. Connect a Scan Tool.
2 3. Turn the ignition to RUN ■ — '
Go to applicable
4. Check for Powertrain DTCs powertrain
Were there any Vehicle Speed DTCs found? DTC table Go to Step 3

1. Connect a Scan Tool.

2. Drive the vehicle for a short test drive while observing
the ATC Data List.
3. Note the value of the Rear Propshaft Speed at a
set speed.
3 4. Change the scan tool screen to reflect the —
Transmission Data List.
5. Compare the Rear Propshaft Speed previously noted
to the Transmission OSS (Output Shaft Speed) at the
same speed.
Are the rpm values approximately equal at the same
speeds? Go to Step 22 Go to Step 4

1. Turn the ignition to OFF.

2. Disconnect the transfer case shift control module
connectors.
3. Connect a J 39200 DMM between transfer case shift
control module harness connector C1 terminals F5
and F6.
4 4. Block the front wheels. 0-0.5 AC V
5. Place the transmission in neutral.
6. Raise and support the rear axle so that the wheels
turn freely.
7. Rotate the rear propshaft by hand while observing the
AC voltage reading on the J 39200 DMM.
Does the voltage vary between the specified values? Go to Step 20 Go to Step 5

1. Disconnect the transfer case rear propshaft speed

sensor.
5 2. Measure the resistance of the rear propshaft speed 1300-2700 0
sensor.
Is the resistance reading within the specified values? Go to Step 6 Go to Step 21
Measure the resistance between transfer case shift control
6 module harness connector C1 terminals F5 and F6. OL
Is the resistance reading less than the specified value? Go to Step 15 Go to Step 7

1. Turn the ignition to Run.

7 2. Measure voltage between transfer case shift control 0V
module connector C1 terminal F6 and ground.
Is the voltage greater than the specified value? Go to Step 16 Go to Step 8
Measure the resistance between transfer case shift control
8 module harness connector C1 terminal F6 and ground. OL
Is the resistance reading less than the specified value? Go to Step 17 Go to Step 9
Measure voltage between transfer case shift control
9 module harness connector C1 terminal F5 to ground. 0V
Is the voltage greater than the specified value? Go to Step 18 Go to Step 10
Measure the resistance between transfer case shift control
10 module harness connector C1 terminal F5 and ground. OL
Is the resistance reading less than the specified value? Go to Step 19 Go to Step 11
 DTC C 0300 R ear Speed S en so r M alfunction i c o n t’d)
Step Actior; Value(s) Yes No
Measure the resistance between transfer case shift control
module harness connector C1 terminal F6 and transfer
11 case rear propshaft speed sensor terminal B. 0-5 Q
Is the resistance reading within the specified values? Go to Step 12 Go to Step 14
Measure the resistance between transfer case shift control
module harness connector C1 terminal F5 and transfer
12 case rear propshaft speed sensor terminal A. 0-5 0
Is the resistance reading within the specified values? Go to Step 22 Go to Step 13
Repair an open in CKT 2221 between the rear propshaft
speed sensor and the transfer case shift control module.
13 Refer to Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair an open in CKT ???? between the rear propshaft
speed sensor and the transfer case shift control module.
14 Refer to Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short between CKT 2221 and CKT ????. Refer to
15 Wiring Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 22
Repair a short to voltage condition in CKT ????. Refer to
16 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short to ground condition in CKT 2222. Refer to
17 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short to voltage condition in CKT 2221. Refer to
18 Wiring Repairs in Wiring Systems. — _
Are the repairs complete? Go to Step 22
Repair a short to ground condition in CKT 2221. Refer to
19 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
20 (Automatic 4WD). — —
Is the repair completed? Go to Step 22
Replace the transfer case rear propshaft speed sensor.
Refer to Speed Sensor Replacement (Rear Speed Sensor
21 Replacement). — —
Is the repair completed? Go to Step 22
Reconnect all ATC system components, make sure all the
components are properly mounted.
22 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 23
Clear all the ATC DTCs. Go to Transfer
23 Are all the ATC DTCs cleared? — Case Diagnostic —
System Check
DTC C0305 Front Speed Sensor Malfunction

■>Transfer
(Case
FSSHI FSSLO I Shift
I Control
1 .1 *>Module
E12 E13 C1

0.5 YEL 400 0.5 PPL 401

&P100

C132

0.5 YEL 400 0.5 PPL 401

B
Front
HI LO
Propshaft
Speed
Sensor

460735

Circuit Description Action Taken When the DTC Sets

The front propshaft speed sensor is a permanent • All Shifts to AUTO (Adapt) mode will be disabled.
magnet (PM) generator. The PM generator produces a If the current mode is AUTO, the system will not
pulsing AC voltage. The AC voltage level and allow any further adaptive events (correct slip).
number of pulses increases as speed increases. The • The SERVICE indicator (AWD/4WD) lamp will be
module converts the pulsating AC voltage to a l atched on for the remainder of the current
propshaft RPM which is used for calculations, and to ignition cycle.
monitor the difference between the front and rear
propshaft speed. It is also used in the AUTO (Adapt) Conditions for Clearing the DTC
mode of operation to determine the amount of slip • The transfer case shift control module will clear
and the percent of torque to apply to the front axle The the DTC if the condition for setting the DTC no
module only looks at this input when the vehicle is longer exists.
in AUTO (Adapt) mode, 4H, and 4L ranges. The
• A history DTC will clear after 100 consecutive
propshaft RPM can be displayed with a scan tool. The
ignition cycles without a fault present.
module only monitors this input when the vehicle is
AUTO, 4H, or 4L. • History DTCs can be cl eared using a scan tool.
This DTC detects an open, short to ground, or faulty Test Description
sensor. The number(s) below refer to the step number(s) on
Conditions for Setting the DTC the diagnostic table.
The system will log the DTC if the front propshaft 4. This step determines if the front speed sensor is
input indicates a speed of less than 16 RPM for able to generate AC current and indicates that
30 seconds while all of the following are true: both the sensor and wiring to the transfer
• The transmission NOT in Park/Neutral. case shift control module is good.
• The engine is running. 5. This step measures the internal resistance of the
• The front axle is engaged. front speed sensor and whether or not it is
• The rear Propshaft speed exceeds 512 RPM. within acceptable l imits.
• The vehicle speed On Class 2 Data bus exceeds 7. This step determines if circuit 401 has a short to
10 mph. voltage.
 DTC C0305 Front Speed Sensor Malfunction
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition OFF.

2. Connect a Scan Tool
2 3. Turn the ignition to RUN. —
Go to applicable
4. Check for Powertrain DTCs. powertrain
Were there any vehicle speed DTCs found? DTC table Go to Siep 3
1. Connect a Scan Tool.
2. Drive the vehicle for a short test drive while observing
the ATC Data List.
3. Note the value of the Front Propshaft Speed at a
3 set speed. —
4. Compare the Front Propshaft Speed previously noted
to the Rear Propshaft Speed at the same speed.
Are the rpm values within 10 percent of each other at the
same speeds? Go to Step 22 Go to Step 4
1. Turn the ignition to OFF.
2. Disconnect the transfer case shift control module
connectors.
3. Connect a J 39200 DMM between transfer case shift
control module harness connector C1 terminals E12
and E13.
4 4. Block the rear wheels. 0-0.5 AC V
5. Place the transmission in neutral.
6. Raise and support the front axle so that the wheels
turn freely.
7. Rotate the propshaft by hand while observing the
AC voltage reading on the DMM.
Does the voltage vary between the specified values? Go to Step 20 Go to Step 5
1. Disconnect the transfer case front propshaft speed
sensor.
5 2. Measure the resistance of the front propshaft speed 1300-2700 0
sensor.
Is the resistance reading within the specified values? Go to Step 6 Go to Step 22
Measure the resistance between transfer case shift control
6 module harness connector C1 terminals E12 and E13. OL
Is the resistance reading less than the specified value? Go to Step 15 Go to Step 07

1. Turn the ignition to RUN.

2. Measure voltage between the transfer case shift
7 control module harness connector C1 terminal E12 ov
and ground.
Is the voltage greater than the specified value? Go to Step 16 Go to Step 8
Measure the resistance between the transfer case shift
control module harness connector C1 terminal E12 and
8 ground. OL
Is the resistance reading less than the specified value? Go to Step 17 Go to Step 9
Measure voltage between the transfer case shift control
9 module harness connector C1 terminal E13 and ground. OV
Is the voltage greater than the specified value? Go to Step 18 Go to Step 10
Measure the resistance between the transfer case shift
control module harness connector C1 terminal E13 and
10 ground. OL
Is the resistance reading less than the specified value? Go to Step 19 Go to Step 11
 DTC C0305 Front Speed Sensor Malfunction (cont’d)
Step Action Value(s) Yes No
Measure the resistance between the transfer case shift
control module harness connector C1 terminal E12 and
11 front propshaft speed sensor terminal A. 0-5 0
Is the resistance reading with in the specified value? Go to Step 12 Go to Step 13
Measure the resistance between the transfer case shift
control module connector C1 terminal E13 and front
12 propshaft speed sensor terminal B. —
Is the resistance reading with in the specified value? Go to Step 22 Go to Step 14
Repair an open in CKT 400 between the front propshaft
speed sensor and the transfer case shift control module.
13 Refer to Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair an open in CKT 401 between the propshaft speed
sensor and the transfer case shift control module. Refer to
14 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short between CKT 400 and CKT 401. Refer to
15 Wiring Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 22
Repair a short to voltage condition in CKT 400. Refer to
16 Wiring Repairs in Wiring Systems. — ■' —
Are the repairs complete? Go to Step 22
Repair a short to ground condition in CKT 400. Refer to
17 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short to voltage condition in CKT 401. Refer to
18 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair a short to ground condition in CKT 401. Refer to
19 Wiring Repairs in Wiring Systems. — —
Are the repairs complete? Go to Step 22
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
20 (Automatic 4WD). — —
Is the action complete? Go to Step 22
Replace the front speed sensor. Refer to Speed Sensor
21 Replacement (Front Speed Sensor Replacement). — —
Is the action complete? Go to Step 22
Reconnect all ATC system components, make sure all the
components are properly mounted.
22 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 23
Clear all the ATC DTCs. Go to Transfer
23 Are all the ATC DTCs cleared? — Case Diagnostic —
System Check
DTC C0308 Motor A/B Circuit Low

t Hot At All Times!

^ Transfer
1Case Shift
1Control
I Module
' >

a" B *02
3 BLK 1552
3 RED 1553
mp --------- --4S ^Pf0O
E, . G , ,C131
3 BLK 1552
3 RED 1553
A, BJ.01
' Encoder
Motor

450736

Circuit Description C onditions fo r C learing the SilL/OIC

The transfer case motor is a bi-directional, permanent • The transfer case shift control module will clear
magnet, DC motor. When energized, (through the DTC if the condition for setting the DTC no
CKTS 1552, 1553, and the ground CKT 150 the longer exists.
module utilize for the motor control), the motor, through • A history DTC will clear after 100 consecutive
a series of gears, rotates a shaft which moves the ignition cycles without a fault present.
mode and range forks to shift the transfer case
• History DTCs can be cleared using a scan tool.
between 4H, AUTO (Adapt), 2H, N, and 4L ranges.
This DTC detects a short to ground on CKT 1552 and Test Description
1553, a shorted motor. The number(s) below refer to the step number(s) on
Conditions for Setting the DTC the diagnostic table.

• The system will test the motor circuits: 2. Listens for an audible motor noise when the
encoder operates. Command both the ON
- The system checks for unwanted voltage. and OFF states. Repeat the commands as
- The system supplies voltage on one necessary.
circuit and reads the voltage back
3. Tests for a short to ground in the Motor Control A
on the other.
circuit or module.
• If the system detects a problem with the circuits,
4. Tests for a short to ground in the Motor Control B
the DTC is logged.
circuit or module.
• The transfer case shift control module senses a
low voltage return on CKT 1552 or 1553 when 5. Tests for a higher than normal resistance in the
a high voltage is expected. Motor Control A and B circuits and through the
module.
Action Taken When the DTC Sets 6. Tests for a short to ground in the encoder motor
• All shifting will be disabled, windings.
• The SERVICE indicator (AWD/4WD) lamp will be
latched on for the remainder of the current
ignition cycle.
7. Tests for continuity across the motor circuit. 9. Tests Motor Control B circuit for a short to ground.
Resistance readings vary depending on the
10. Tests Motor Control A and B circuits for an open
location of brush contact inside the motor
or high resistance.
assembly.
8. Tests Motor Control A circuit for a short to ground.
DTC C 0308 Motor A/Bi C ircuit Low
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Install a scan tool.
2. Turn the ignition ON, with the engine OFF.
2 3. With the scan tool, command the Motor A/B control —
ON and OFF. Go to
Does the Encoder Motor turn ON and OFF? Diagnostic Aids Go to Step 3
1. Turn the ignition OFF.
2. Disconnect the four wire connector at the
transfer case.
3 3. Connect a J 39200 Digital Multimeter DMM between 10 K O
the Motor Control A circuit harness connector 01
terminal A and ground at the transfer case.
Is the resistance reading less than the specified value? Go to Step 8 Go to Step 4
Connect a DMM between the Motor Control B circuit
harness connector C1 terminal B and ground at the
4 transfer case. 10 KO
Is the resistance reading less than the specified value? Go to Step 9 Go to Step 5
Connect a DMM between the Motor Control A and B
circuit harness connector C1 terminals A and B at the
5 transfer case. 20
Is the resistance reading less than the specified value? Go to Step 10 Go to Step 6
Test terminals A and B at the transfer cas side of the
6 harness for a short to ground. —
Was a problem found? Go to Step 11 Go to Step 7
Test for continuity across the motor circuit.
7 —
Was there continuity? Go to Step 12 Go to Step 11
1. Disconnect the transfer case shift control module.
8 2. Test Motor Control A circuit harness connector C1 —
terminal A for a short to ground.
Was the condition found and corrected? Go to Step 13 Go to Step 12 ..
1, Disconnect the transfer case shift control module.
9 2, Test Motor Control B circuit harness connector C1
terminal B for a short to ground.
Was the condition found and corrected? Go to Step 13 Go to Step 12
1. Disconnect the transfer case shift control module.
10 2. Test Motor Control A and B circuit harness connector —
C1 terminals A and B for an open or high resistance.
Was the condition found and corrected? Go to Step 13 Go to Step 12
Replace the transfer case encoder motor. Refer to
11 Motor/Encoder Replacement (Automatic 4WD). — —
Are the repairs complete? Go to Step 13
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
12 — —
(Automatic 4WD).
Are the repairs complete? Go to Step 13
1. Use the scan tool in order to clear the DTCs.
13 2. Operate the vehicle within the Conditions for Running —
the DTC as specified in the supporting text.
Does the DTC reset? Go to Step 2 System OK
 I Hot At All Times |
11
I Power -4 - 1
, Distribution T CASE
1 Cell 10 Fuse 2 1
I 20 A I
i I
Fuse Block 3 ORN 1840 ^ "■
Details
Cell 10
3 ORN 1640
D C2
r —- T ignition” 1 Transfer
1 1Case Shift
1 I 1Control
i 1- f — ..1----- \ « • Module
i -f i \
i 1 *
iM
L_ a L. —j
A % § ' "02
8 BLK 1552
3 RED 1553
^ pioo-
EyX G / %C131-
3 BLK ■ 1552
3 RED 1553
A, B, . Cl
P _ _ .
^Encoder
1 - Motor
I i
I — S @ [— i
i i

450736

Circuit Description Action Taken When the DTC Sets

The transfer case motor is a bi-directional, permanent • All shifting will be disabled.
magnet, DC motor. When energized, (through • The SERVICE indicator (AWD/4WD) lamp will be
CKT 1552, 1553, and the ground CKT 2150, -the latched on for the remainder of the current
module utilize for motor control), the motor, through a ignition cycle.
series of gears, rotates a shaft which moves the
mode and range forks to shift the transfer case Conditions for Clearing the DTC
between 4H, Adapt, 2H, N, and 4L ranges. • The transfer case shift control module will clear
This DTC detects a short to Voltage on CKTS 1552 the DTC if the condition for setting the DTC no
and 1553, a shorted motor. longer exists.
• A history DTC will clear after 100 consecutive
Conditions for Setting the DTC
ignition cycles without a fault present.
• The system will test the motor circuits by reading
• History DTCs can be cleared using a scan tool.
the voltage on each circuit.
• If the system detects a problem with the circuits, Test Description
the DTC is logged. The number(s) below refer to the step number(s) on
• The transfer case shift control module senses a the diagnostic table.
high voltage on CKTS 1552 or 1553 when a 2. This step determines if there is a short to voltage
low voltage is expected. on circuit 1552.
 DTC C0309 Motor A/B Circuit High
Step Action Vaiue(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect both transfer case shift control module
connectors.
2 3. Connect a J 39200 Digital Multimeter DMM between OV
the transfer case shift control module harness
connector C2 terminal A and ground.
4. Turn the ignition to RUN.
Is the voltage reading greater than the specified value? Go to Step 3 Go to Step 5
1. Turn the ignition OFF.
2. Disconnect the transfer case encoder motor.
3. Connect the J 39200 DMM between the transfer case
3 shift control module harness connector C2 terminals 0V
A and ground.
4. Turn the ignition to RUN.
Is the voltage reading greater than the specified value? Go to Step 4 Go to Step 6
Repair a short to voltage in CKT 1552. Refer to Wiring
4 Repairs in Wiring Systems. — :—
Is the repair complete? Go to Step 7
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
5 — ■_
(Automatic 4WD).
Is the repair complete? Go to Step 7
Repair a short to voltage in CKT 1553. Refer to Wiring
6 Repairs in Wiring Systems. —- .
Is the repair complete? Go to Step 7
1. Ensure the ignition is OFF.
7 2. Reconnect all previously disconnected components. — . —
Are all the ATC components connected and properly
mounted? Go to Step 8
Clear all ATC DTCs. Go to Transfer
8 Are all the ATC DTCs cleared? — Case Diagnostic —
System Check
 |Hot At All Times I

I Power < i
„ Distribution T CASE
jj Cell 10 Fuse 2 i
20 A 1
I i
la e-33 1
=3m*mmm .J
Fuse Block 3 ORN 1640
Details
Cell 10
3 ORN 1640
D .02
‘ Ignition 3 "* Transfer
* Case Shift
I Control
t; I Module
* >

1Encoder
! Motor

450736

C ircu it D escription A ction Taken W hen the DTC Sets

The transfer case motor is a bi-directional, permanent • All shifting will be disabled.
magnet, DC motor. When energized, (through
• The SERVICE indicator (AWD/4WD) lamp will be
CKTS 1552, 1553, and the ground CKT 150, the
module utilize for motor control), the motor, through a latched on for the remainder of the current
series of gears, rotates a shaft which moves the ignition cycle.
mode and range forks to shift the transfer case C onditions fo r C learing the DTC
between 4H, AUTO (Adapt), 2H, N, and 4L ranges.
This DTC detects an open on CKTS 1552 and • The transfer case shift control module will clear
1553, an open motor. the DTC if the condition for setting the DTC no
longer exists.
C on d itio ns fo r Setting th e DTC
• A history DTC will clear after 100 consecutive
• The system will test the motor circuits by checking ignition cycles without a fault present.
for unwanted voltage.
• History DTCs can be cleared using a scan tool.
• The system supplies voltage on each of the motor
circuits and reads the voltage back on the other T est D escription
circuit.
The number(s) below refer to the step number(s) on
• If the system detects a problem with the circuits, the diagnostic table.
the DTC is logged. The transfer case shift
control module senses a low voltage return on 4. This step determines if circuit 1552 is open.
CKTS 1552 or 1553 when a high voltage is 5. This step determines if circuit 1553 is open.
expected.
 DTC C0310 Motor A/B Circuit Open
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Disconnect the transfer case encoder motor.

2. Inspect the transfer case encoder motor harness
2 connector. —
3. Check the terminals for proper connection.
Are the terminals damaged or corroded? Go to Step 8 Go to Step 3
Use a J 39200 Digital Multimeter DMM to measure
3 resistance across the encoder motor. 2-10 Q
Is the resistance measured within the specified values? Go to Step 4 Go to Step 7
1. Disconnect the transfer case shift control module
connectors.
4 2. Measure the resistance between the transfer case 0-10 0
shift control module harness connector C2 terminal A
and the encoder motor harness connector terminal A.
Is the resistance measured within the specified values? Go to Step 5 Go to Step 9
Measure the resistance between the transfer case shift
control module harness connector C2 terminal B and the
5 encoder motor harness connector terminal B. 0-5 O
Is the resistance measured within the specified values? Go to Step 6 Go to Step 10
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
6 (Automatic 4WD). — —
Is the repair complete? Go to Step 11
Replace the transfer case encoder motor. Refer to
7 Motor/Encoder Replacement (Automatic 4WD). —
Are the repairs complete? Go to Step 11
Repair the harness connector. Refer to Connector Repairs
8 in Wiring Systems. — —
Are the repairs complete? Go to Step 11
Repair open in CKT 1552. Refer to Wiring Repairs in
9 Wiring Systems. — —
Are the repairs complete? Go to Step 11
Repair open in CKT 1553. Refer to Wiring Repairs in
10 Wiring Systems. ■ —■ —
Are the repairs complete? Go to Step 11
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
11 disconnected ATC components. — ■—
Have all the ATC components been reconnected and
properly mounted? Go to Step 12
Clear all ATC DTCs Go to Transfer
12 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
 |Hot AtAHTimes]

I Power <
ip
, Distribution T CASE jFuse
1 Cell 10 Fuse 2 Block
i DBT 20 A
i

3 ORN 1640
Fuse Block
Details I---- --- S236
Cell 10
8 ORN 1640
D. C2
Transfer
Battery Case Shift
Feed Control
Module
Case Ground

c w C2

3 BLK 150

Ground
Distributio n S204
Cell 14

3 BLK 150

lG200

450737

Circuit Description Action Taken When the DTC Sets

The transfer case motor is a bi-directional, permanent 1. All shifting will be disabled.
magnet, DC motor. When energized, (through
2. The SERVICE indicator (AWD/4WD) lamp will be
CKTS 1552, 1553, and the ground CKT 150, the
module utilize for motor control), the motor, through a latched on for the remainder of the current
series of gears, rotates a shaft which moves the ignition cycle.
mode and range forks to shift the transfer case Conditions for Clearing the DTC
between 4H, AUTO (Adapt), 2H, N, and 4L ranges.
• The transfer case shift control module will clear
This DTC detects an open ground CKT 150.
the DTC if the condition for setting the DTC no
Conditions for Setting the DTC longer exists.
The system test the motor circuits: • A history DTC will clear after 100 consecutive
• The system checks for unwanted voltage. ignition cycles without a fault present.
• The system supplies voltage on each of the motor • History DTCs can be cleared using a scan tool.
circuits and reads the voltage back on the other
circuit. Test Description
• The system checks for opens and shorts on the The number(s) below refer to the step number(s) on
motor circuits, its applies voltage to the motor the diagnostic table.
and the voltage on the ground circuit.
2. This step determines if there is an open in
• If the system detects a high voltage return on the circuit 150.
ground circuit, the DTC is logged. The transfer
case shift control module senses a low voltage
return on CKT 150 when a low voltage is
expected.
 DTC C0315 Motor Ground Circuit Open
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? Case Diagnostic
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect connector C2 at the transfer case shift
control module.
2 3. Use a J 39200 Digital Multimeter DMM in order to 0-5 0
measure the resistance between harness
connector C2 terminal C to ground.
Is the resistance reading within the specified values? Go to Step 4 Go to Step 3
Repair a loose or open in ground CKT 150 between the
transfer case shift control module and splice pack SP 204.
3 Refer to Wiring Repairs in Wiring Systems. —
Is the repair complete? Go to Step 5
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
4 (Automatic 4WD). — —
Is the repair complete? Go to Step 5
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
5 disconnected ATC components. —• —
Have all the ATC components been reconnected and
properly mounted? Go to Step 6
Clear all ATC DTCs. Go to Transfer
6 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
 Hot At All Times
r — — _ i|R
I Power
. Distribution
ion E7 K T CASE | Fuse
1 Cell 10 Fuss 2 Block
DiC 20 A 1
i
:J
3 ORN 1640
S236 Details
Ceil 10
Transfer
1 1Case Shift
1Control
T-C ase! M ° d u le
'Look >

iJ L lA A
E1 T C1
0.5 TAN 1569 °-80RN 1640
« - - - --------- € S P100
C131
0.8 ORN 1640
0.8 TAN 1589
C1
0.8 ORN 1640
0.8 TAN 1669
1 Encoder
I Motor
I
I
Brake
Control
I

450741

Circuit Description Action Taken When the DTC Sets

The transfer case shift control module controls the • All shifting will be disabled.
transfer case lock solenoid.
• The SERVICE indicator (AWD/4WD) lamp will be
The lock is energized (locking action released, latched on for the remainder of the current
grounding CKT 1569) during gear shifts and in AUTO ignition cycle.
(Adapt) mode of operation. When power or ground
is removed from the lock solenoid, (locking action Conditions for Clearing the DTC
applied), the transfer case motor is prevented from
• The transfer case shift control module will clear
moving. In this manner, the system is capable of
the DTC if the condition for setting the DTC no
providing a 4H and 4L lock-up without the need of
longer exists.
additional vehicle power to hold the transfer case in
these positions. • A history DTC will clear after 100 consecutive
This DTC detects an open lock solenoid coil, ignition cycles without a fault present.
CKT 1569 open, open feed (CKT 1640) to the • History DTCs can be cl eared using a scan tool.
solenoid.
Test Description
Conditions for Setting the DTC
The number(s) below refer to the step number(s) on
• The system will try to turn the lock solenoid off by the diagnostic table.
opening the ground circuit.
2. This step determines if battery voltage exists on
• I f the module is unable to de-energize the circuit 1640.
solenoid, the system will not attempt to
de-energize the solenoid again during that 4. This step determines if the internal resistance of
ignition cycle. the encoder motor lock circuit is within specified
limits.
• Auto transfer case lock output reads back as a
low voltage when a high voltage is expected. 6. This step determines whether circuit 1569 is open.
 DTC C0323 T-Case Lock Circuit Low
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition to the OFF position.

2. Disconnect the transfer case encoder motor harness.
2 3. Connect a J 39200 Digital Multimeter DMM from the 9-14 V
encoder motor harness connector C1 terminal C to
ground in order to measure the voltage.
Is the voltage with in the specified values? Go to Step 4 Go to Step 3
Repair an open in CKT 1640 between splice S236 and the
transfer case encoder motor. Refer to Wiring Repairs in
3 Wiring Systems. — —
Are the repairs complete? Go to Step 11
Use a J 39200 DMM in order to measure the resistance
4 across the encoder motor lock circuit. 20-80 O
Is the resistance reading within the specified values? Go to Step 5 Go to Step 7
1. Disconnect the transfer case shift control module
connectors.
5 2. Use the J 39200 DMM in order to measure the OL
resistance between transfer case shift control module
connector C1 terminal E1 and ground.
Is the resistance reading less than the specified value? Go to Step 8 Go to Step 6
Measure the resistance between transfer case shift control
module connector C1 terminal E1 and the transfer case
6 encoder motor connector C1 terminal D. 0-5 0
Is the resistance reading within the specified values? Go to Step 10 Go to Step 9
Replace the transfer case encoder motor (lock solenoid).
7 Refer to Motor/Encoder Replacement (Automatic 4WD). — —-
Is the repair completed? Go to Step 11
Repair an short to ground in CKT 1569. Refer to Wiring
8 Repairs \n Wiring Systems. — —
Are the repairs complete? Go to Step 11
Repair an open in CKT 1569. Refer to Wiring Repairs in
9 Wiring Systems. — —
Are the repairs complete? Go to Step 11
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
10 (Automatic 4WD).
Is the repair completed? Go to Step 11
Reconnect all ATC system components, make sure all the
components are properly mounted.
11 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 12
Clear all the ATC DTCs. Go to Transfer
12 Are all the ATC DTCs cleared? Case Diagnostic —
System Check
 jHotAtAniTr^
r — — • i|p
I Power
. Distributio n T CASE •Fuse
1 Cell 10 FuseS Block
20 A

3 ORN 1640
Fuss Block
S23S Details
Cell 10
Transfer
1Case Shift
1Control
T-C ase j Module
Lock
L j lill
El €1
0.8 ORN 1640
0.5 TAN 1569
S P100
C. C131
0.80RN 1640
0.8 TAN 1589
D . C Cl
o.s o r n 1640
0.8 TAN 1569
11Encoder
1Motor

Brake
Control

450741

Circuit Description Action Taken When the DTC Sets

• The system will try to turn the lock solenoid on,
The transfer case shift control module controls the
grounding CKT 1569; if unable to energize the
transfer case lock solenoid. The lock is energized solenoid, the system wil l not attempt to energize
(locking action released, by grounding CKT 1569) the solenoid again during that ignition cycle.
during gear shifts and in AUTO (Adapt) mode • All shifting will be disabled.
of operation. When power or ground is removed from • The SERVICE indicator (AWD/4WD) lamp will be
the lock solenoid (locking action applied, rel easing latched on for the remainder of current
the ground on CKT 1569), the transfer case motor is ignition cycle.
prevented from moving. In this manner the system
Conditions for Clearing the DTC
is capable of providing a 4H and 4L lock-up without the
• The transfer case shift control module will clear
need of additional vehicle power to hold the transfer
the DTC if the condition for setting the DTC no
case in these positions. longer exists.
This DTC detects a shorted lock solenoid coil, • A history DTC will clear after 100 consecutive
CKT 1569 shorted to a 12 V circuit. ignition cycles without a fault present.
• History DTCs can be cleared using a scan tool.
Conditions for Setting the DTC
Test Description
Transfer Case Lock Solenoid output reads back as a The number(s) below refer to the step number(s) on
high voltage when a low voltage is expected. the diagnostic table.
2. This step determines if the internal resistance of
the encoder motor lock circuit is within the
specified resistance.
3. This step determines if circuit 1569 is shorted to
voltage.
 DTC C0324 T-Case Lock Circuit High
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Disconnect the transfer case encoder motor harness.
2. Use a J 39200 Digital Multimeter DMM in order to
2 measure the resistance across the encoder motor 20-80 0
lock circuit.
Is the resistance reading within the specified values? Go to Step 3 Go to Step 4
1. Turn the ignition to the OFF position.
2. Disconnect the transfer case shift control module
connectors.
3 3. Connect a J 39200 DMM from the transfer case shift 0V
control module harness connector C1 terminal E1 to
ground in order to measure voltage.
4. Turn the ignition to the run position.
Is the voltage greater than the specified value? Go to Step 6 Go to Step 5
Replace the transfer case encoder motor (lock solenoid).
4 Refer to Motor/Encoder Replacement (Automatic 4WD). ■'—
Is the repair complete? Go to Step 7
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
5 (Automatic 4WD). — —
Is the repair complete? Go to Step 7
Repair a short to voltage condition in CKT 1569. Refer to
6 Wiring Repairs in Wiring Systems.
Are the repairs complete? Go to Step 7
Reconnect all ATC system components, make sure all
components are properly mounted.
7 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 8
Clear all the ATC DTCs. Go to Transfer
8 Are all the ATC DTCs cleared? — ' Case Diagnostic
System Check
DTC C0327 Encoder Circuit Malfunction

' ^ Transfer Case

1Shift Control
i Encoder
1 8V Encoder
1Module
1 Power „ Ground

1 I
V ------- ‘---- Z. —*v
_ _ F13 E5 E8 E7 ■ -E6 F12 ,C2 .
0.5
LT GRN/ 431 0.5 DK BLU/WHT 1557 0.5 RED/WHT 1556 ■
BLK 0.5 YEL/BLK 1558
0.5 BRN/WHT 1555 0.5 BLK/WHT 1554
&P100
C H G132
0.5 :
LT GRN/ 431 0*5 DK BLU/WHT 1557 0.5 RED/WHT 1558
BLK 0.5 BRN/WHT 1555 0,5 YEL/BLK 1558 0,5 BLK/WHT 1554-
P B D A c m
~ “ 1 Encoder
Motor
; Hal!..j «99 Hall • u .j Hall '[ hsIT"
Effect | Effect Effect I Effect
_________ f V™, *

450747

Circuit Description . Action Taken When the DTC Sets

The transfer case encoder is a switch that converts a • All motor activity wil l stop and the transfer case
shaft position, representing a mode or range lock engaged.
position, into electrical signals for use by the transfer • A default rail to rail shift may be allowed, (toggle
case shift control module. The encoder houses 4 between 4H and 2H).
Hall effect sensors that are used for channels P, A, B,
• The SERVICE indicator (AWD/4WD) lamp will be
and C. These sensors provide a path to ground,
latched on for the remainder of the current
when a magnet, (part of the shift rail), passes
ignition cycle.
over them.
The transfer case shift control module supplies an Conditions for Clearing the DTC
8 V reference and a ground circuit for the encoder Hall • The transfer case shift control modul e will clear
effect sensors to function via GKT 431 and 1554 the DTC if the condition for setting the DTC no
respectfully. longer exists.
The transfer case shift controlmodule supplies 5 V on • A history DTC will clear after 100 consecutive
all the channels, thus as these channels are pulled ignition cycles without a fault present.
to ground, the module can interpret the location of the • History DTCs can be cleared using a scan tool.
transfer case shift position.
Test Description
This DTC detects an open, short to ground, or a short
to voltage (12 V) in CKT 431, an open in CKT 1554, The number(s) below refer to the step number(s) on
an open, short to ground, or short to voltage (12 V) in the diagnostic table.
the encoder channel CKTS 1555, 1557, 1558, 2. This test will help to isolate whether or not the
or 1556. fault exits in the transfer case motor encoder.
Conditions for Setting the DTC 3. This test will determine if the suspect encoder
The transfer case shift control module reads back all circuit is shorted to ground.
high or low voltage on the encoder channel circuits. 6. This test will help determine if one or more
encoder channels are shorted together.
8. This test will determine if the suspect encoder ; 14. This test determines if CKT 431 is shorted
circuit is open. to power.

DTC C0327 Encoder Circuit Malfunction

Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? ' — Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool and select the transfer case

data list.
2. Turn ignition to RUN.
2 . —
3. Observe the states of the Encoder Circuit P, A, B
and C.
Do all circuits display OFF? Go to Step 5 Go to Step 3
1. Identify which Encoder Circuit stays ON.
2. Disconnect both transfer case shift control module
connectors.
3 OL
3. Use a J 39200 Digital Multimeter DMM to measure
the resistance in the suspect circuit to ground.
Is the resistance reading less than the specified value? Go to Step 4 Go to Step 21
Repair short to ground in the suspect circuit. Refer to
4 Wiring Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 22
Use a J 39200 DMM to measure voltage between transfer
5 case encoder harness connector C1 terminal E and A. 7-9 V
Is the voltage within the specified values? Go to Step 6 Go to Step 13
1. Use the Scan Tool to monitor the states of the
Encoder Circuit P, A, B and C.
2. Individually jumper the transfer case encoder harness
6 connector C1 terminals F, B, D and C (one terminal at . _
a time) to terminal A.
Does more than one Encoder Circuit display ON
simultaneously? Go to Step 10 Go to Step 7
Do all the circuits display ON when their individual circuit is
7 —
jumped to terminal A? Go to Step 11 Go to Step 8
1. Identify which Encoder Circuit stays OFF.
2. Disconnect both transfer case shift control module
connectors.
8 3. Use a J 39200 DMM to measure the resistance 0-5 0
across the suspect circuit.
Is the resistance reading across the suspect circuit within
the specified values? Go to Step 21 Go to Step 9
Repair open in the suspect circuit. Refer to Wiring Repairs
9 in Wiring Systems. — ■
Is the repair complete? Go to Step 22
Repair a shorted condition between the circuits that were
simultaneously turn ON in Step 6. Refer to Wiring Repairs
10 in Wiring Systems. — ■ —
Are the repairs complete? Go to Step 22
Use a J 39200 DMM to measure voltage between transfer
case encoder harness connector C1 terminals F, B, D
11 and C to terminal A. 4.8-5.1 V
Is the voltage within the specified values? Go to Step 12 Go to Step 21
Replace transfer case encoder. Refer to Motor/Encoder
12 Replacement (Automatic 4WD). — —
Is the action complete? Go to Step 22
Was the voltage reading previously measured in Step 5
13 —
greater than 9 volts? Go to Step 14 Go to Step 15
 DTC C0327 Encoder Circuit Malfunction (cont’d)
Step Action Value(s) Yes No
1. Disconnect both transfer case shift control module
connectors.
2. Turn the ignition to RUN.
14 3. Use a J 39200 DMM to measure voltage from 0-0.5 V
transfer case encoder harness connector C1
terminal E to ground.
Is the voltage reading within the specified values? Go to Step 21 Go to Step 17
Use a J 39200 DMM to measure resistance from transfer
15 case encoder harness connector C1 terminal A to ground. 0-5 0
Is the resistance reading within the specified values? Go to Step 16 Go to Step 18
1. Disconnect both transfer case shift control module
connectors.
2. Use a J 39200 DMM to measure resistance from
16 transfer case shift control module harness 0-5 O
connector C1 terminal F13 to the transfer case
encoder harness connector C1 terminal E.
Is the resistance reading within the specified values? Go to Step 22 Go to Step 20
Repair short to power in CKT 431. Refer to Wiring Repairs
17 in Wiring Systems. — ■ —
Are the repairs complete? Go to Step 22
1. Disconnect both transfer case shift control module
connectors.
2. Use a J 39200 DMM to measure resistance from
18 . transfer case shift control module connector C1 0-5 0 ■
terminal F12 to encoder motor harness connector C2
terminal A..
Is the resistance reading within the specified values? Go to Step 21 Go to Step 19
Repair open in CKT 1554. Refer to Wiring Repairs in
19 Wiring Systems. — —
Are the repairs complete? Go to Step 22
Repair open in CKT 431. Refer to Wiring Repairs in Wiring
20 Systems. ■ —
Are the repairs complete? Go to Step 22
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
21 (Automatic 4WD). — —
Is the action complete? Go to Step 22
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
22 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 23
Clear all ATC DTCs. Go to Transfer
23 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
DTC C0357 Park Switch Circuit High

1Hot In RUN And START |

p-------------- 1 -------------- r “ "* Transfer
1 1 1P I
H4 JL TURN B/U Fuse j Case Shift
I / 3 Fuse 16 Block 1 Control
1 J3 > 20 A I
1 1 Module
Ib tm_ .
Turn/ ■0.8 PNK / 0.8 LTGRN F15 J Cl
Hazard
F lash ers 139 275
0.8 PNK 139
C7, ,C100
/ €266
0,8 PNK 139
C C1
0.8 DKGRN/WHT 1135
■■ Park/
1Neutral . A
\ Brake/
B Cl (Closed in Transmission
0.8 LT GRN
2 7 5 park only) Shift Interlock
(BTSI)
&P101 Solenoid
C200 B
0,8 BLK 150
/C227 0.8 C2BB
DKGRN/WHT 1135
0.8 LTGRN 275 0.8 BLK 150
E C277 Ground
r ~ ■>Stoplamp S204II- - Distribution
Cell 14
1 • Switch
I 1 (Shown w/brak 0.8 3 BLK 150
i. —A i not applied)
DKGRN/ 1135
WHT
fi _________ G200
450803

Circuit Description Action Taken When the DTC Sets

The park switch supplies a 12 V input to the module • Whenever PARK/NEUTRAL was true, the module
would believe the transmission was in PARK.
when the vehicle is in PARK. The modul e uses
• All range shifts will be disabled.
this input to determine if the vehicle is in
PARK/NEUTRAL. If the vehicle is in PARK, the • The SERVICE indicator (AWD/4WD) l amp will be
latched on for the remainder of the current
module will not allow a range shift from 2H, 4H, or
ignition cycle.
AUTO (Adapt) mode to 4L range.
Conditions for Clearing the DTC
This DTC detects voltage on CKT 275 (LT GRN) at • The transfer case shift control module will clear
the module when the module sees a front or rear the DTC if the condition for setting the DTC no
propshaft speed signal, or vehicle speed form longer exists.
the VCM/PCM over the Class 2 data bus. • A history DTC will clear after 100 consecutive
ignition cycles without a fault present.
Conditions for Setting the DTC
• History DTCs can be cl eared using a scan tool .
The transfer case shift control module detects voltage Test Description
on CKT 584 at the module when the module sees The number(s) below refer to the step number(s) on
a front or rear propshaft speed signal, or vehicle speed the diagnostic table.
form the VCM over the Class 2 data bus 10 mph or 4. This step determines if circuit 275 is shorted to
over for 10 consecutive seconds. voltage.
 DTC C0357 Park Switch Circuit High
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? ._ Case Diagnostic
Go to Step 2 System Check
1. Disconnect the PARK/NEUTRAL position switch.
2. Turn the ignition ON, engine OFF.
2 3. Use the Scan Tool in order to read the Park Switch —
states.
Does the scan tool indicate an open switch? Go to Step 4 Go to Step 3
Replace the PARK/NEUTRAL Position Switch. Refer to
Park/Neutral Back Up Switch Replacement for 4L60E
3 Transmissions or 4L80E Transmissions. —
Is the action complete? Go to Step 7
1. Disconnect the transfer case shift control module
connectors.
4 2. Connect a J 39200 Digital Multimeter DMM between 0-0.5 V
the transfer case shift control module connector C1
terminal F15 to ground.
Is the voltage within the specified values? Go to Step 5 Go to Step 6
Repair a short to voltage in CKT 275. Refer to Wiring
5 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 7
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
6 (Automatic 4WD). —
Is the action complete? Go to Step 7
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
7 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 8
Clear all ATC DTCs Go to Transfer
8 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
D aG C0362 4 L O Discrete Output Circuit High

1Vehicle 1Powertrain
! Control Control
Module Module
[(VCM) J(PCM)
I ign
ta mmmmmmaj u l0r>
23 T C4 D2 TCI

Gas I Diesel

0.5 GRY/BLK 1694

*P101(Wesel)
C120

0,8 GRY/BLK 1694

D €131

iPIQQ

0.6 GRY/BLK 1694

F7 Cl
Transfer
1Case Shift '
.V 1Control A
1Module ifeA
4WDLO I

450753

Circuit Description Action Taken When the DTC Sets

CKT 1694 is used to notify the vehicle control module • May affect the transmission shift points.
(VCM) powertrain control module (PCM) that the • The SERVICE indicator (AWD/4WD) lamp will be
vehicle is in 4WD l ow range. The vehicle control latched on for the remainder of the current
module (VCM) powertrain control module (PCM) ignition cycle.
supplies 12 V on this circuit. The transfer case shift Conditions for Clearing the DTC
control module supplies a ground on this circuit when • The transfer case shift control module will clear
the vehicle is in 4WD low range. the DTC if the condition for setting the DTC no
This DTC detects an transfer case shift control module longer exits.
problem, a short to voltage on CKT 1694. • A history DTC will clear after 100 consecutive
ignition cycles without a fault present.
Conditions for Setting the DTC • History DTCs can be cleared using a scan tool.
• After the system turns the output on, (grounding Test Description
CKT 1694), and reads back a high voltage, the The number(s) below refer to the step number(s) on
DTC is set. The system will not attempt it the diagnostic table.
again during that ignition cycle. 2. This step determines if the transfer case shift
• The transfer case shift control module reads back control module is receiving the specified voltage
a high voltage when a low voltage is expected from the Powertrain Control Module (PCM).
on the 4 low discrete output, CKT 1694. 4. This step determines if circuit 1694 has a short to
voltage.
 DTC C0362 4LO Discrete Output Circuit High
' Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition OFF.

2. Disconnect both transfer case shift control module
connectors.
2 3. Turn the ignition ON, engine OFF. 11-13.5 V
4. Use a DMM in order to measure the voltage between
the transfer case shift control module connector C1
terminal F7 to ground.
Is the voltage reading within the specified values? Go to Step 3 Go to Step 4
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
3 (Automatic 4WD). —- —
Is the action complete? Go to Step 7
1. Turn the ignition OFF.
2. Disconnect the Vehicle Control Module
(VCM)/Powertrain Control Module (PCM) connectors.
4 3. Turn the ignition ON. 11-13.5 V
4. Use a DMM in order to measure the voltage between
the transfer case shift control module connector C1
terminal F7 to ground.
Is the voltage reading within the specified value? Go to Step 5 Go to Step t
Repair a short to voltage in CKT 1694. Refer to Wiring
5 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 7
Replace the Powertrain Control Module (PCM). Refer to
PCM Replacement/Programming and VCM
6 Replacement/Programming. — —
Is the action complete? Go to Step 7
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
7 disconnected ATC components. ■ —. —
Have all the ATC components been reconnected and
properly mounted? Go to Step 8
Clear all ATC DTCs. Go to Transfer
8 Have all the ATC DTCs been cleared? Case Diagnostic —
System Check
DTC C0367 Front Axle Control Circuit High

450757

Circuit Description Conditions for Clearing the DTC

The transfer case shift control module controls the • The transfer case shift control module will dear
engagement and disengagement of the front axle by the DTC if the condition for setting the DTC no
grounding (engaging) CKT 1570. The front axle wil l be longer exists.
disengaged in 2H and neutral only, it should be
engaged in the all other modes. This DTC detects a • A history DTC will clear after 100 consecutive
shorted actuator, a short to 12 V on CKT 1570. ignition cycle without a fault present.
• History DTCs can be cleared using a scan tool.
Conditions for Setting the DTC
• The system will try to engage the front axle. If it Test Description
can not engage the front axle, the system will The number(s) below refer to the step number(s) on
not attempt it again during that ignition cycle. the diagnostic table.
• The transfer case shift control module reads back
the front axle output as a high voltage when a 2. This test will determine if CKT 1570 is shorted to
low voltage is expected. voltage.

Action Taken When the DTC Sets 4. This test will determine if whether the short to
voltage in CKT 1570 is the result of an internal
• All shifting for 4WD and AUTO (Adapt) mode will short to power within the transfer case shift control
be disabled. module.
• The SERVICE indicator (AWD/4WD) lamp will be
latched on for the remainder of the current
ignition cycle.
 DTC C0367 Front Axle Control Circuit High
Step Action Val ue(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Turn the ignition OFF.
2. Disconnect front axle switch/actuator connector.
3. Connect a J 39200 Digital Multimeter DMM from the
2 front axle actuator harness connector terminal B to 0-0.5 V
ground.
4. Turn the ignition to RUN, engine OFF.
Is the voltage reading greater than the specified values? Go to Step 4 Go to Step 3
Replace the front axle switch/actuator. Refer to Electric
3 Motor Actuator Replacement —, —
Is the repair complete? Go to Step 7
1. Turn the ignition OFF.
2. Disconnect both transfer case shift control module
4 harness connectors.
0-0.5 V
3. Connect a J 39200 DMM between the front axle
actuator harness connector terminal B to ground.
Is the voltage reading greater than the specified values? Go to Step 5 Go to Step 6
Repair short to voltage in CKT 1570. Refer to Wiring
5 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 7
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
6 (Automatic 4WD) — —
Is the action complete? Go to Step 7
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
7 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 8
Clear all ATC DTCs. Go to Transfer
8 Have all the ATC DTCs been cleared? ■ — Case Diagnostic —
System Check
DTC C0374 General System Malfunction
Circuit Description Conditions for Clearing the MIL/DTC
• A history DTC will clear after 100 consecutive
The transfer case shift control module senses rear to
ignition cycles without a fault present.
front slip, a difference of rear to front wheel speed,
• Use a scan tool in order to clear history and
attempts to correct the difference by turning on
current DTCs.
the motor, internal to the transfer case, to apply torque
to the front wheels. Test Description
The number(s) below refer to the step number(s) on
Conditions for Setting the DTC the diagnostic table.
2. This test checks for proper operation of the serial
The transfer case shift control module is unable to
data line.
correct sensed slip for 10 consecutive seconds.
3. This test will identify the stored diagnostic trouble
codes and whether or not they are current or
history.
5. The SERVICE indicator (AW D/4W D) lamp should
turn off after approximately 2 seconds.

DTC C0374 General System Malfunction

Step Action Vaiue(s) s He

Important: If DTC C0300 or C0305 is also present

perform the diagnostic for these DTCs before continuing. Go to Transfer
1
Was the Transfer Case Diagnostic System Check Case Diagnostic
performed? Go to Step 2 System Check

1. Place transmission in PARK.

2. Turn the Ignition to the RUN position.
2 3. Connect the Scan Tool. —
4. Use the Scan Tool to command Encoder Motor A and
Encoder Motor B On.
Is the encoder motor turning on (buzzing noise)? Go to Step 5 Go to Step 3
1. Turn the ignition OFF.
2. Disconnect the wire harness at the encoder motor.
3 3. Turn the ignition switch to RUN. —
4. Use the Scan Tool to check for DTCs.
Did DTC COS10 set? Go to Step 7 Go to Step 4
Replace transfer case shift control module. Refer to
Transfer Case Control Module Replacement
4 (Automatic 4WD). — —
Has the transfer case shift control module been replaced? Go to Step 8
1. Using the Scan Tool manually command gear
position by using the device control for the ATC Mode
Switch.
5 2. Use the Increase and Decrease buttons on the scan —
tool to command through all the Mode Switch states
while observing Encoder Gear Position.
Does the Encoder Gear Position state change as
commanded by the scan tool? Go to Step 6 Go to Step 7
Remove transfer case and overhaul. Refer to Transfer
Case - New Venture Gear 246 in the Transmission Unit
6 Repair Manual (TURM). —
Are the repairs complete? Go to Step 8
Replace the transfer case encoder motor. Refer to
7 Motor/Encoder Replacement (Automatic 4WD) — ■— -
Is the repair complete? Go to Step 8
Clear all ATC DTCs. Go to Transfer
8 — Case Diagnostic —
Have all the ATC DTCs been cleared?
System Check
DTC C0376 Front/Rear Shaft Speed Mismatch

'' Transfer
•Case
1 FSS HI FSS LO RSSLQ RSS HI I Shift
| I I Control [ST I
^ - T - r - .r .- * - - J Module | \ |
E12 E lif PS w
f G1 i i4A
0.5 DKGRN 2222.
0.5 YEL 400
0.5 PPL 401 0.5 LT BLU 2221

» P100

, 9 B, K , _________ ^ ,C132

0.5 YEL 400 0.5 DK GRN 2222

0.5 PPL 401
0.5 LT BLU 2221

B B A
4V Front J Rear
Propshaft Propshaft
HI LO LO HI
Speed Speed
Sensor Sensor

450760

Circuit Description • The front propshaft or rear propshaft speed

The front and rear propshaft speed sensor is a exceeds 512 RPM.
permanent magnet (PM) generator. The PM generator • the vehicle speed On Class 2 Data bus exceeds
produces a pulsing AC voltage. The AC voltage 10 mph.
level and number of pulses increases as speed Action Taken When the DTC Sets
increases. The module converts the pulsating AC
voltage to a propshaft RPM which is used for • All Shifts to AUTO (Adapt) mode will be disabled.
calculations. The module only l ooks at these inputs If the current mode is AUTO, the system will not
together when the vehicle is in 4H, 4L, and AUTO allow any further adaptive events (correct slip).
(Adapt) range only. The propshaft RPM can be • The SERVICE indicator (AWD/4WD) lamp will be
displayed with a scan tool. latched on for the remainder of the current
This DTC detects greater than 20% difference in the ignition cycle.
speed sensor inputs. Conditions for Clearing the DTC
Conditions for Setting the DTC • The transfer case shift control module will clear
the DTC if the condition for setting the DTC no
The transfer case shift control modul e detects
longer exists.
continued readings of front and rear propshaft speed
signal which do not match. Module can not determine • A history DTC will clear after 100 consecutive
propshaft speed. ignition cycles without a fault present.
The system will log the DTC if the front and rear • History DTCs can be cleared using a scan tool.
propshaft inputs indicates a speed of less than 20% Test Description
difference for 40 seconds while all of the The number(s) below refer to the step number(s) on
following are true: the diagnostic table.
• the transmission NOT in Park/Neutral. 4. This step attempt to determine whether a fault
• The engine is running. exists in the rear propshaft speed sensor circuit.
• The front axl e is engaged. 5. This step attempts to determine whether a fault
• The front propshaft indicates speed less exists in the front propshaft speed sensor
than 75 mph. circuit.
 DTC C0376 Front/Rear Shaft Speed Mismatch
Step Action Value(s) Yes No

Important: If DTC C0300 is also present perform the

1 diagnostic for DTC C0300 before continuing. Go to Transfer
—
Was the Transfer Case Diagnostic System Check Case Diagnostic
performed? Go to Step 2 System Check

1. Turn the ignition OFF.

2. Inspect the following for a mismatch;
• Front and rear axle ratios
• All tires
• Front or rear propshaft missing
2 —
3. Inspect that the speed sensors are wired correctly by
comparing vehicle wire harness to the system
schematics.
Inspect the connectors for proper connection and for
loose terminals.
Was a problem found? Go to Step 6 Go to Step 3

1. Turn the ignition OFF.

2. Connect a Scan Tool.
3 3. Turn the ignition to RUN. —
Go to applicable
4. Check for Powertrain DTCs. powertrain
Were there any Vehicle speed DTCs found? DTC table Go to Step 4

1. Connect a Scan Tool.

2. Drive the vehicle while observing the ATC data list.
3. Note the value of the rear propshaft speed at a
set speed.
4. Change the scan tool screen to reflect the
4 Transmission Data List. —
5. Compare the rear propshaft speed previously noted
to the Transmission OSS (Output Shaft Speed) at the
same speed.
Are the rpm values approximately equal at the same
speeds? Go to Step 5 Go to Step 7

1. Continue driving the vehicle while observing the ATC

data list.
5 2. Compare the rear propshaft speed to the front —
propshaft speed at the same speed. «
Are the rpm values approximately equal at the same
speeds? Go to Step 8 Go to Step 9
Repair/replace as necessary.
6 — —
Is the action complete? Go to Step 10
Replace the transfer case rear vehicle speed sensor.
Refer to Speed Sensor Replacement (Front Speed Sensor
7 Replacement). — —
Are the repairs complete? Go to Step 10
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
8 (Automatic 4WD). — •—
Are the repairs complete? Go to Step 10
Inspect/replace the front transfer case vehicle speed
sensor reluctor wheel for damage, misalignment, and
9 slipping. —
Are the repairs complete? Go to Step 10
 D T C C 0 3 7 6 Front/Rear Shaft Speed Mismatch (eont’d)
Step , Action , Value(s) : Yes No
1. Ensure that the ignition is OFF.
10 2. Properly mount and reconnect all ATC components. — —
Have a ll the ATC components been reconnected and
properly mounted? Go to Step 11
Clear all ATC codes. Go to Transfer
11 Have all the ATC codes been cleared? — Case Diagnostic —
System Check

D TC C 0 5 5 0 ECU M a lfu n c tio n

Circuit Description • ROM code has failed checksum test indicating
At each power up the module runs a self test on the that ROM data is no longer valid.
following: • One or more RAM locations have failed
• EEPROM Checksum operational test indicating that some portions of
RAM are not functional.
• ROM Checksum
• Motor circuit test has indicated that one of the
• RAM Checksum module’s relays is not able to make contact.
• RAM Malfunction
Action Taken When the DTC Sets
• Relay Malfunction
The SERVICE indicator (AWD/4WD) lamp will be
Conditions for Setting the DTC latched on and the system will be disabled.
• Critical operational parameters stored in EEPROM Conditions for Clearing the DTC
have failed checksum test indicating invalid data.
• Replace the transfer case shift control module.
• Masked ROM code has failed checksum test
indicating that masked ROM data is no • Perform the Transfer Case Diagnostic
longer valid. System Check.
D TC C 0 6 1 1 V IN In fo rm a tio n E rro r
Circuit Description Action Taken When the DTC Sets
The transfer case shift control module uses the VIN • The ignition counts since last fault will be cleared.
information for calculations that are required for
• The system will be disabled until valid VIN data
the different calibrations used based on axl e ratio,
transmission, tire size, and engine. The system does is received.
not know which calibration to use without this • The SERVICE indicator (AWD/4WD) lamp will be
information. latched on.
Conditions for Setting the DTC Conditions for Clearing the DTC
The transfer case shift control module does not A history DTC will clear after a valid VIN digit is
receive a valid VIN digit for the correct application, K received.
truck, L van or T truck within 2 seconds after
power up.
DTC C0611 VIN Information Error
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
Using a Scan Tool, check all the components connected to Go to Data Link
the Class 2 serial data line. Refer to Data Link Communications
2 Communications System Check — System Check in
Is the Class 2 serial data line communicating properly? Electrical
Go to Step 3 Diagnosis.
Check the VCM EEPROM calibration. Go to A
Is the PCM calibration correct? Powertrain On
Board Diagnostic
(OBD) System
Check for 4.3L,
A Powertrain On
Board Diagnostic
3 (OBD) System
Check for 5.0,
5.7L, and A
Powertrain On
Board Diagnostic
(OBD) System
Go to Step 4 Check for 6.5L
Check the transfer case shift control module for the correct
part number.
4 —
Is the transfer case shift control module part number
correct? Go to Step 5 StepS
Replace the transfer shift control module with the correct
part number. Go to Transfer ■
5 —
Have ail the ATC components been reconnected and Case Diagnostic
properly mounted? System Check
DTC C0895 Device Voltage Malfunction
I Hot At All Times |
.r -Jip
I Power
. Distributio n T CASE Fuse
1 Cell 10 Fuse 2 [Block
i D8** 20 A
! I
:«S
3*ORN 1640
Details S236
Cell 10
3 ORN 1640
D C2
’ Transfer
Electronics Case Shift
Ground
, Control
i Module

E16TC1
1 BLK/WHT 451
Ground
Distribution »-------- O S215
Cell 14
1 BLK/WHT 451
C200
SP100
1 BLK/WHT 451
Ground SI 03
Distribution ► ------- <►
Cell 14

1 BLK/WHT 451 1 BLK/WHT 451

A 6 1 0 3 lG104
(Gas Engines) (Gas and Diesel Engines)

450764

Circuit Description Action Taken When the DTC Sets

The direct battery supply l ine (circuit 1640) provides There are no default actions associated with this DTC.
The SERVICE AWD/4WD lamp will not be latched on.
the power to the modul e and motor circuitry.
Conditions for Clearing the DTC
This DTC detects a intermittent absence of battery • Current DTC
voltage at the modul e when the module sees an
The transfer case shift control module will clear
ignition on voltage. the DTC if the condition for setting the DTC
no longer exists.
Conditions for Setting the DTC
• History DTC
The transfer case shift control module did not power - Once 100 consecutive ignition cycles without
up 8 out of the l ast 19 ignition cycl es. a fault present.
- You issue a scan tool CLEAR CODES
command.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
4. This step determines if an intermittent open exists
in circuit 1640.
6. This step determines if an intermittent open exists
in circuit 1640.
 DTC G0895 Device Voltage Malfunction
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to
1 performed? T r a n s fe r C a s e
D ia g n o s tic
Go to S t e p 2 S y s te m C h e c k
Inspect the ATC Fuse in the Underhood Bussed Electrical
2 Center. —
Is the fuse good? Go to S t e p 9 Go to S t e p 3
1. Replace fuse.
2. Turn the ignition switch to the RUN position for
10 seconds.
3 3. Turn the ignition switch to the OFF position. —
4. Remove the ATC Fuse.
5. Inspect the fuse.
Is the fuse good? Go to S t e p 4 Go to S t e p 9
1. Disconnect connector C2 at the transfer case shift
control module.
2. Connect a J 3 9 2 0 0 DMM from cavity D (ORN) 1640 to
4 ground and check for voltage. 9-14 V
3. While observing the DMM display wiggle the wire
harness.
Did the DMM display ever drop below battery voltage? Go to S t e p 5 Go to S t e p 6
Repair a open condition in CKT 1640.
5 —
Are the repairs complete? Go to S t e p 1 2
1. Connect the J 3 9 2 0 0 from cavity C (BLK) 150 to
ground and check for resistance.
6 2. While observing the J 3 9 2 0 0 display wiggle the wire 0-5 Q
harness.
Is the resistance measured ever greater than the specified
values? Go to S t e p 7 Go to S t e p 8
Repair an open or poor ground condition in CKT 150. Refer
7 to Wiring Repairs in Electrical Diagnosis. — —
Are the repairs complete? Go to S t e p 1 2
Replace the transfer case shift control module. Refer to
T r a n s fe r C a s e C o n tr o l M o d u le R e p la c e m e n t
8 (A u to m a tic 4 W D ) . — —
Is the action complete? Go to S t e p 1 2
1. Turn Ignition switch to the OFF position.
2. Disconnect connectors C1 at the underhood bussed
electrical center and C2 at the shift control module.
3. Connect a J 3 9 2 0 0 from cavity D 1640 to ground and
9 check for resistance. OL
4. While observing the DMM display wiggle the wire
harness.
Is the resistance measured ever less than the
specified value? Go to S t e p 11 Go to S t e p 1 0
1. Replace the transfer case shift control module. Refer
to transfer case shift control module replacement.
10 — —
2. Replace ATC Fuse.
Are the repairs complete? Go to S t e p 1 2
1. Repair a short to ground condition in CKT 1640.
11 2. Replace the ATC Fuse. — —
Are the repairs complete? Go to S t e p 1 2
 DTC C0895 Device Voltage Malfunction (cont’d)
Step Action Value(s) Yes No
Reconnect all ATC system components, make sure all the
components are properly mounted.
12 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 13
Clear all ATC codes. Go to Transfer
13 Have all the ATC codes been cleared? — Case Diagnostic —
System Check
Front Axle W ill Not Engage

T e st D e scrip tio n 5. This step determines if the transfer case shift

The number(s) below refer to the step number(s) on contral module is able to sense volta9e on
the diagnostic table. CKT 1695.
3. This step determines if the front axle actuator has
a good power and ground supplied to it.
4. This step determines if the transfer case shift
control module is providing the ground signal
to the front axle actuator through terminal B in
order to drive the front axle actuator motor.
Front Axle Will Not Engage
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition ON, engine OFF.

2. Connect a Scan Tool in order to monitor Front Axle
2 Switch status. —
3. Use the Scan Tool to engage the front Axle.
Does the Front Axle Switch display change from Unlocked
to Locked? Go to Step 6 Go to Step 3
 Front Axle Will Not Engage (cont’d)
Step Action Value(s) Yes No
1. Turn the ignition Off.
2. Disconnect the harness connector at the Front Axle
Actuator.
3 3. Turn the ignition switch On, engine Off. 9-14 v
4. Connect a J 39200 Digital Multimeter DMM between
harness connector terminals C and E at the Front
Axle Actuator.
Is the voltage within the value specified? Go to Step 4 Go to Step 9
1. Connect a J 39200 DMM between Front Axle
Actuator harness connector terminals B and C.
4 2. Monitor the voltage reading on the J 39200 DMM 9-14 V
while using the Scan Tool in order to engage the
front axle.
Is the voltage reading within the specified values? Go to Step 5 Go to Step 14
1. Connect a jumper wire between the front axle
actuator harness connector terminals A and C.
5 2. Use the Scan Tool in order to read the Front Axle —
Switch status.
Does the Scan Tool show the Front Axle Switch status
Locked? Go to Step 17 Go to Step 7
Inspect the front axle for mechanical concerns, if no
mechanical concerns are present replace the Front Axle
6 Actuator. —
Is the repair complete? Go to Step 19
1. Disconnect the connectors at the transfer case shift
control module.
7 2. Connect a J 39200 DMM between transfer case shift 0-0.5 V
control module harness connector C1 terminal E14
and front axle actuator harness connector terminal A.
Is the resistance reading within the specified values? Go to Step 16 Go to Step 8
Repair open in CKT 1695. Refer to Wiring Repairs in
8 Wiring Systems. — —
Is the repair complete? Go to Step 19
1. Connect a J 39200 DMM between Front Axle
Actuator harness connector terminals C and ground.
9 9-14 V
2. Observe the voltage reading on the J 39200 DMM.
Is the voltage reading within the specified values? Go to Step 10 Go to Step 11
Repair open in CKT 2150. Refer to Wiring Repairs in
10 Wiring Systems. — —
Is the repair complete? Go to Step 19
Inspect the 4WD fuse in CKT 241 for continuity.
11 —
Is the fuse good? Go to Step 12 Go to Step 13
Repair open in CKT 241. Refer to Wiring Repairs in Wiring
12 Systems. . — . —
Is the repair complete? Go to Step 19
1. Replace 4WD fuse in CKT 241.
13 2. Turn the ignition On, engine Off.
—
3. Wait 2 minutes and reinspect the fuse.
Is the fuse good? Go to Step 19 Go to Step 18
 Front Axle Will Not Engage (cont’d)
Step Action Value(s) Yes No

1. Disconnect the connectors at the transfer case shift

control module.
14 2. Connect a J 39200 DMM between transfer case shift 0-5 0
control module harness connector C1 terminal F4 and
front axle actuator harness connector terminal B.
Is the resistance reading within the specified values? Go to Step 16 Go to Step 15
Repair open in CKT 1296. Refer to Wiring Repairs in
15 Wiring Systems. —' —
Is the repair complete? Go to Step 19
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
16 (Automatic 4WD). — —
Is the action complete? Go to Step 19
Replace the front axle actuator. Refer to Electric Motor
17 Actuator Replacement — —
Is the action complete? Go to Step 19
Repair short to ground in CKT 241. Refer to Wiring
18 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 19

1. Ensure the ignition is OFF.

2. Properly mount and reconnect all previously
19 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 20
Clear all ATC DTCs. Go to Transfer
20 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
Front Axle Will Not Disengage

• Front
] Motor Motor f S235<Gas)
Control fy Engaged Disengaged H
1570
Electronics

0,8 Front E 0.8 BLK 150

BLK/ 1695 Axle 0.8 BLK 150
WHT Actuator C. 12Q
C
S302

Drain 1 BLK 150

Wire Ground
Distribution ^SI-62" ■
Front 1 transfer Cell 14
5 BLK 150 '
Axie 1Case Shift
switch sControl A >8147
1Module J b A 1 BLK 150
[
&G105

450757

Test Description 5. This step determines if the transfer case shift

control module is able to sense voltage on
The number(s) below refer to the step number(s) on
CKT 1695.
the diagnostic table.
6. This step determines if the front axle switch is
3. This step determines if the front axle actuator has suppling power to the transfer case shift
a good power and ground supplied to it. control module.
’ 4. This step determines if the transfer case shift
control module is providing the ground signal
to the front axle actuator through terminal B in
order to drive the front axle actuator motor.
 Front Axle Will Not Disengage
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? - — Case Diagnostic
Go to Step 2 System Check

1. Turn the ignition On, engine Off.

2. Ensure that the vehicle is in 2WD mode.
2 3. Use the Scan Tool in order to read the Front Axle —
Switch status.
Does the Scan Tool show the Front Axle Switch status
Locked? Go to Step 6 Go to Step 3

1. Turn the ignition Off.

2. Disconnect the harness connector at the Front Axle
Actuator.
3 3. Turn the ignition switch On, engine Off. 9-14 V
4. Connect a J 39200 Digital Multimeter DMM between
harness connector terminals C and E at the Front
Axle Actuator.
Is the voltage within the value specified? Go to Step 4 Go to Step 12

1. Connect a J 39200 DMM between Front Axle

Actuator harness connector terminals B and C.
4 2. Monitor the voltage reading on the J 39200 DMM 9-14 V
while using the Scan Tool in order to engage the
front axle.
Is the voltage reading within the specified value? Go to Step 5 Go to Step 17

1. Connect a jumper wire between Front Axle Actuator

harness connector terminals A and C.
5 2. Use the Scan Tool in order to read the Front Axle —
Switch status.
Does the Scan Tool show the Front Axle Switch status
Locked? Go to Step 20 Go to Step 10

1. Disconnect the Front Axle Actuator connector.

2. Use the Scan Tool in order to read the Front Axle
6 Switch status. _
Does the Scan Tool show the Front Axle Switch status
Locked? Go to Step 8 Go to Step 7
Inspect the front axle for mechanical concerns, if no
mechanical concerns are present replace the Front Axle _ ■
7 Actuator. --
Is the repair complete? Go to Step 22

1. Connect a J 39200 DMM between Front Axle

Actuator harness connector terminals A and E.
8 0-0 5 V
2. Observe the voltage reading on the J 39200 DMM.
Is the voltage reading within the specified values? Go to Step 19 Go to Step 9
Repair a short to voltage in CKT 1695. Refer to Wiring
9 Repairs in Wiring Systems. —
Is the repair complete? Go to Step 22

1. Disconnect the connectors at the transfer case shift

control module.
10 2. Connect a J 39200 DMM between transfer case shift 0-5 0
control module harness connector C1 terminal E14
and front axle actuator harness connector terminal A.
Is the resistance reading within the specified values? Go to Step 19 Go to Step 11
Repair open in CKT 1695. Refer to Wiring Repairs in
11 Wiring Systems. — —
Is the repair complete? Go to Step 22
 Front Axle Will Not Disengage (cont’d)
Step Action Value(s) Yes No
1. Connect a J 39200 DMM between Front Axle
Actuator harness connector terminals C and ground.
12 9-14 V
2. Observe the voltage reading on the J 39200 DMM.
Is the voltage reading within the specified values? Go to Step 13 Go to Step 14
Repair open in CKT 2150. Refer to Wiring Repairs in
13 Wiring Systems. — —
Is the repair complete? Go to Step 22
Inspect the 4WD fuse in CKT 241 for continuity. Refer to
14 Wiring Repairs in Wiring Systems. —
Is the fuse good? Go to Step 15 Go to Step 16
Repair open in CKT 241. Refer to Wiring Repairs in Wiring
15 Systems. —. —
Is the repair complete? Go to Step 22
1. Replace 4WD fuse in CKT 241.
2. Turn the ignition On, engine Off.
16 —
3. Wait 2 minutes and reinspect the fuse.
Is the fuse good? Go to Step 22 Go to Step 21
1. Disconnect the connectors at the transfer case shift
control module.
17 2. Connect a J 39200 DMM between transfer case shift 0-5 0
control module harness connector C1 terminal F4 and
front axle actuator harness connector terminal B.
Is the resistance reading within the specified values? Go to Step 19 Go to Step 18
Repair open in CKT 1296. Refer to Wiring Repairs in
18 Wiring Systems. — —
Is the repair complete? Go to Step 22
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
19 (Automatic 4WD). — —
Is the action complete? Go to Step 22
Replace the front axle actuator. Refer to Electric Motor
20 Actuator Replacement — —
Is the action complete? Go to Step 22
Repair short to ground in CKT 241. Refer to Wiring
21 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 22

1. Ensure that the ignition is OFF.

2, Properly mount and reconnect all previously
22 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 23
Clear all ATC DTCs. Go to Transfer
23 Case Diagnostic . __
Have all the ATC DTCs been cleared?
System Check
 1 Transfer
Case
Select
Switch

1 Transfer
'" T " JCase
+8VDC
REG Shift
Control
j Module

A
450729

Circuit Description Neutral may be obtained if the following conditions

are met:
The range/mode switch circuit consists of 4 normally
open switches. The transfer case shift control • The engine is running.
module supplies a regulated 8 volt DC to the switch • The automatic transmission is in neutral (or the
through CKT 431. The switch has CKT 1693 to return clutch pedal is depressed on a manual
current to the transfer case shift control module transmission application).
through a 9.09 K resistor located inside the switch. • The vehicle speed is below 3 MPH.
The transfer case shift control module constantly • The transfer case is in the 2HI mode.
monitors this signal voltage to determine the condition Once these conditions have been met, pressing and
of the mode switch circuit. If no buttons are pressed, holding both the 2HI and 4LO buttons for 10 seconds
and the transfer case shift control module detects will shift the transfer case into neutral, turning on
a voltage level outside the possible range (approx. the red neutral indicator lamp.
0.5-1.0 volts) for longer than 5 minutes, the transfer Test Description
case shift control module will set this DTC or if a button The number(s) below refer to the step number(s) on
is held down or sticks for a period longer the diagnostic table.
than 5 minutes. When each of the switches is 2. This step determines if the transfer case shift
depressed they will complete a circuit through their control module is receiving an input from the
own specific resistor. The transfer case shift control Mode/Range Switch.
module continuously monitors the switch input to 3. This step determines if the inability to change
determine whether the 4HI, AUTO 4WD, 2HI, and 4LO ranges is due to a faulty switch or transfer
button selectors are made by the driver. case shift control module.
 Range/Mode Switch Inoperative
Step ction Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check
1. Connect a Scan Tool.
2. Turn the ignition to RUN, engine ON.
3. Place transmission into neutral (or clutch pedal
depressed on manual transmission applications).
4. Set Parking Brake.
Important: Neutral Range will only be obtained by
2 pressing and holding both the 2HI and 4LO buttons —
simultaneously for 10 seconds. Refer to Circuit
Description.
5. Observe Commanded Mode Indicator states on the
Scan Tool while depressing each of the Mode/Range
buttons.
Does the state change with the press of any of the
Mode/Range buttons? Go to Step 5 Go to Step 3
1. Use a Scan Tool in order to command through the
ranges of the Mode/Range Switch.
3 2. Continue to observe Commanded Mode Indicator
states on the Scan Tool while commanding through
all ranges.
Does the Mode Indicator state change? Go to Step 5 Go to Step 4
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
4 (Automatic 4WD). — —
Is the action complete? Go to Step 6
Replace the Mode/Range Switch. Refer to Transfer Case
5 Driver Control Switch Replacement (Automatic 4WD). — —
Is the action complete? Go to Step 6
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
6 disconnected ATC components. — ■—
Have all the ATC components been reconnected and
properly mounted? Go to Step 7
Clear ail ATC DTCs. Go to Transfer
7 Have all the ATC DTCs been cleared? — ' Case Diagnostic
System Check
No C o rre c tio n fo r S lip in A W D M o d e
Test Description 3. This step determines if the front axle switch is
The number(s) below refer to the step number(s) on Locked during AWD mode.
the diagnostic table. 4. This step determines if there is a mechanical
2. The front axle switch should be in the Locked failure or a faulty transfer case shift control
position while the vehicle is in the 4WD mode. module.
This step determines if the front axle switch
is Locked during 4WD mode.
No Correction for Slip in AWD Mode
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool.

2. Turn the engine ON.
2 3. Ensure the vehicle is in 4WD mode. —
4. Use the Scan Tool in order to view the state of the
Front Axle Switch, Go to Front Axle
Is the Front Axle Switch Locked? Go to Step 3 Will Not Engage

1. Change Range/Mode state to AWD.

2. Use the Scan Tool in order to view the state of the
3 Front Axle Switch.
Does the state of the Front Axle Switch continue to display
Locked? Go to Step 4 Go to Step 6
1. Change Range/Mode state to back to 4WD mode.
2. Drive the vehicle for a short test drive while observing
the ATC Data List.
3. Note the values of the Front and Rear Propshaft
4 Speed at a set speed. —
4. Compare the Front and Rear Propshaft Speed
previously noted at the same speed.
Are the rpm values approximately equal at the same
speeds? Go to Step 6 Go to Step S
Inspect front axle and transfer case for mechanical failure.
5 Repair/replace as needed. —
Are the repairs complete? Go to Step 7
Replace transfer case shift control module. Refer to
Transfer Case Control Module Replacement
0 — —
(Automatic 4WD).
Is the action complete? Go to Step 7
Reconnect all ATC system components, make sure all the
components are properly mounted.
7 —
Have all the ATC components been reconnected and
properly mounted? Go to Step 8
Clear all the ATC DTCs. Go to Transfer
8 Are all the ATC DTCs cleared? Case Diagnostic —
System Check
Switch Indicator Lamps Flash Continuously

Switch Indicator Lamps Flash Continuously

Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to T r a n s fe r
1 performed? — C a s e D ia g n o s tic
Go to S t e p 2 S y s te m C h e c k
1. Turn the ignition ON, engine OFF.
2. Connect a S c a n T o o l in order to determine Front Axle
2 Switch status. —
Does the Front Axle Switch status show the front axle
Locked? Go to S t e p 6 Go to S te p 3
Continue to use the S c a n T o o l in order to determine if the
transfer case is in Auto 4WD, 4WD HI or 4WD Low mode.
3 —
Is the transfer case in Auto 4WD, 4WD HI or
4WD Low mode? Go to S t e p 4 Go to S te p 1 3

1. Disconnect the connectors at the transfer case shift

control module.
2. Turn the ignition ON, engine OFF.
4 9-14 V
3. Measure the voltage between the transfer case shift
control module connector C1 terminal F4.
Is the voltage within the specified values? Go to S t e p 1 3 Go to S te p 5
Connect a J 3 9 2 0 0 Digital Multimeter DMM between the
transfer case shift control module harness connector C1
5 terminal F4 and the front axle actuator terminal A. 0-5 0
Is the resistance reading within the specified values? Go to S t e p 1 4 Go to S te p 11
 Switch Indicator Lamps Flash Continuously (cont’d)
Step Action ■ Value(s) Yes No
Continue to use the Scan Tool in order to determine if the
6 transfer case is in 2WD mode. 0-5 0
Is the transfer case in 2WD mode? Go to Step 7 Go to Step 13
1. Disconnect connectors at the transfer case shift
control module.
7 2. Measure the voltage between the transfer case shift OV
control module harness connector C1 terminal F4 and
ground.
Is the voltage reading within the specified value? Go to Step 13 Go to Step 8
1. Disconnect the Front Axle Actuator connector.
8 2. Measure the voltage between the Front Axle Actuator OV
harness connector terminal A and Ground.
Is the voltage reading within the specified value? Go to Step 9 Go to Step 12
Inspect the front axle to determine if the front axle is
9 mechanically applied. —
Is the front axle mechanically applied? Go to Step 10 Go to Step 14
Service the front axle for a mechanical failure.
10 — —
Is the repairs complete? Go to Step 16
Repair an open in CKT 1695. Refer to Wiring Repairs in
11 wiring systems. — —
Is the repair complete? Go to Step 16
Repair a short to voltage in CKT 1695. Refer to Wiring
12 Repairs in wiring systems. — —
Is the repair complete? Go to Step 16
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
13 (Automatic 4WD). — —
Is the repair complete? Go to Step 16
Replace the front axle actuator. Refer to Indicator Switch
14 Replacement — — .
Is the repair complete? Go to Step 16
Replace the front drive axle clutch solenoid. Refer to
15 Electric Motor Actuator Replacement — ' — :■ .
Is the repair complete? Go to Step 16
Reconnect all ATC system components, make sure all the
components are properly mounted.
16 — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 17
Clear all the ATC DTCs. Go to Transfer
17 Are all the ATC DTCs been cleared? — Case Diagnostic —
System Check
Switch Indicator Lamps Remain ON - Two or More

Fuss Block
Details
Cell 10

■* Transfer
Case
Select
Switch

%
1) %
J___
S'C2 P%
r— 'ci
0,35 0,35
1560 LT GRN/ 1503 PPL/WHT 1565
BLK 0.35
0.35 PNK 1561 TAN/BLK 1586
F3 _______ E?. . ________ 1 ^ ^ ________ F2^ V.--— -------FI.A. C1
1 Transfer
1Case
\ \ ' I Shift A
r i T
1Control A
Neutral Lamp 4WD Lamp 2HLamp 4H Lamp 4L Lamp 1Module M A
,j
450766

Test Description 4. This step determines which indicator lamp the

The number(s) below refer to the step number(s) on transfer case shift control module is
the diagnostic table. correctly commanding on.
2. This step determines if the transfer case shift 5. This step determines whether there is a short to
control module can electronically control the ground in one of the indicator lamp control
all indicator lamp circuits. circuits.
 Switch Indicator Lamps Remain ON - Tw o or More
Step Action 9 Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? ' — Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool.

2. Turn the ignition ON, engine OFF.
2 3. Use the Scan Tool in order to command all the — ■
indicator lamps off.
Do all the lamps go off? Go to Step 3 Go to Step 4
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
3 (Automatic 4WD). — . —
Is the repair complete? Go to Step 9
1. Use the Scan Tool in order to determine which mode
the transfer case is in.
2. Use this information to determine which lamp
circuit(s) is at fault.
3. Disconnect both connectors at the Range/Mode
4 switch. OL
4. Connect a J 39200 Digital Multimeter DMM and
check for resistance from the Range/Mode switch
harness connector terminal(s) of the suspected
circuit(s) to ground.
Is the resistance reading within the specified value? Go to Step 7 Go to Step 5
1. Disconnect both connectors at the transfer case shift
control module.
2. Connect a J 39200 Digital Multimeter DMM and
5 check for resistance from the Range/Mode switch OL
harness connector terminal(s) of the suspected
circuit(s) to ground.
Is the resistance reading within the specified value? Go to Step 8 Go to Step 6
Repair a short to ground condition. Refer to Wiring Repairs
6 in Wiring Systems. — — '
Are the repairs complete? Go to Step 9
Replace the range/mode switch. Refer to Transfer Case
7 Driver Control Switch Replacement (Automatic 4WD). — —
Is the action complete? Go to Step 9
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
8 (Automatic 4WD). — —

Is the action complete? Go to Step 9

1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
9 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 10
Clear all ATC DTCs. Go to Transfer
10 Have all ATC DTCs been cleared? — Case Diagnostic —
System Check
Switch Indicator Lamps Do Not Light - One or More

jij otlnRun

I Power *4
, Distribution 4WD
Cell 10 Fuse 24
wr i 20 A

Kiss Block
0.8 BRN 241
Details - - i IS235
Cell 10
0.8 BRN 241
c j [C2
11Transfer
SOLID STATE Case
Select
Switch

________ i _____ _ _ j _____ _____ j __________ . i ________ j _ _ :

V N
D 02 F r " i v " V C1
0,35/ e ! 0.35
0.35 BRN 1560 LTGRN/ 1563 PPUWHT 1565
BLK 0.35
0.35 PNK 1561 TAN/BLK 1566
F3 A . ----------------------------------
E3J V ___________ E4J ___ ________ F 2 ^ ^ _______ F1_ Cl
1 Transfer
1Case
\
...» \
r..» I Shift A
Neutral Lamp 4WD Lamp
i
2H Lamp
4
4H Lamp 4LLamp
I Control A
I Module
,J

Test Description 4. This step provides a ground to the indicator lamp

The number(s) below refer to the step number(s) on circuits in order to eliminate the transfer case
the diagnostic table. shift control module.
2. This step determines if the transfer case shift 5. This step checks for B+ in the indicator lamp
control module has electronic control of the switch circuits.
indicator lamps.
 Switch Indicator Lamps Do Not Light - One or More
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool.

2. Turn the ignition to RUN, engine OFF.
2 3. Use the Scan Tool in order to command each of the —
switch indicator lamps On.
Do the switch indicator lamps turn On? Go to Step 7 Go to Step 3

1. Use the Scan Tool to view the ATC Data List.

2. Observe the states of the Indicator Lamps.
3 3. Use the Scan Tool in order to command each of the —
switch indicator lamps On.
Do each of the switch indicator lamp states change from
OFF to ON as Indicator Lamps are commanded ON? Go to Step 7 Go to Step 4

1. Disconnect both connectors at the transfer case shift

control module.
4 2. Use a fused jumper wire in order to jump to ground —
each of the indicator lamp circuits.
Do each of the lamps illuminate when its circuit is
grounded? Go to Step 7 Go to Step 5
Connect a J 39200 Digital Multimeter DMM between the
5 suspect circuit and ground in order to measure voltage. 9-14 V
Is the voltage within the specified value? Go to Step 8 Go to Step 6
Inspect the suspect circuit(s) for open. Refer to Wiring
6 Repairs in Wiring Systems. —
Were the suspected circuit(s) open? Go to Step 9 Go to Step 8
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
7 (Automatic 4WD). — —
Is the action complete? Go to Step 10
Replace the range/mode switch. Refer to Transfer Case
8 Driver Control Switch Replacement (Automatic 4WD). — —
Is the action complete? Go to Step 10
Repair an open in the suspect circuit(s). Refer to Wiring
9 Repairs in Wiring Systems. — —
Is the repair complete? Go to Step 10

1. Ensure the ignition is OFF.

2. Properly mount and reconnect all previously
10 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 11
Clear all ATC DTCs. Go to Transfer
11 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
 I Hot In ON, Bulb Test And START

I Power *#-
. Distribution m k GAUGES 1
1 Cell 10 Fuse 4 I
J7C, 10 A 1
1

0,8 PNK 39
Fuse Block
Details ■S218
Cell 10
0.35 PNK 3S
22 ^
■insvurm ” “ T " " " 1JCluster
11Cluster ^— 4
1Cell 01 I
\ Service |
I GW 4) W
1 - D-
i
L —, —
24"

0.35 LT BLU/BLK

450722

Test Description 3. This step determines if there is an internal short to

The number(s) below refer to the step number(s) on ground in the transfer case shift control module.
the diagnostic table. 4. This step determines if CKT 1567 is shorted to
2. This step determines if the transfer case shift ground.
control module has electronic control of the
Service Indicator.
 Service Indicator Stays ON When Key is ON
Step Action Value(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? — Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool.

2. Turn the ignition to RUN, engine OFF.
2 3. Use the Scan Tool in order to command the Service —
Indicator Off.
Does the Service Indicator turn Off? Go to Step 7 Go to Step 3
Disconnect both connectors at the transfer case shift
3 control module. —
Does the Service Indicator turn Off? Go to Step 7 Go to Step 4
1. Disconnect the connector at the Instrument cluster.
2. Connect a J 39200 Digital Multimeter DMM and
4 measure the resistance between the Instrument OL
Cluster harness connector terminal 24 and ground.
Is the resistance within the specified value? Go to Step 5 Go to Step 6
Service Instrument Cluster for short to ground condition.
5 — —
Is the action complete? Go to Step 8
Repair a short to ground in CKT 1567. Refer to Wiring
6 Repairs in Wiring Systems. —
Is the repair complete? Go to Step 8
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
■ 7 (Automatic 4WD). — —
Is the action complete? Go to Step 8

1. Ensure the ignition is OFF.

2. Properly mount and reconnect all previously
8 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 9
Clear all ATC DTCs. Go to Transfer
9 Have all the ATC DTCs been cleared? — Case Diagnostic —■
System Check
Service Indicator Does Not Light

I Hot In ON, Bulb Test And START [

I Power
1 __
< ---------
.H8 k
1 I
Distribution m k1 ftA1 i irsce
GAUGES I
Call 10 Fuss 4
9 10 A

0,8 PNK
Fuse Block
Details 1S213
Cell 10
0.35 PNK 39
22
■ Instrument 1 1nstrument
1Cluster 1Cluster
I Cell 81 I
i ' 4WD
I
1 I
L J
24

0.35 LT BLU/BLK 1567

E2 Cl
r indicator"! Transfer
* Lamp 1Case Shift
1 Output 1Control
1 Module

450722

Test Description 4. This step check CKT 1567 for open.

The number(s) below refer to the step number(s) on 5. This step check CKT 39 for open,
the diagnostic table.
2. This step determines if the transfer case shift
control module has electronic control of the
Service Indicator.
3. This step determines if there is an internal fault
with the transfer case shift control module.
 Service Indicator Does Not Light
Step Action Val ue(s) Yes No
Was the Transfer Case Diagnostic System Check Go to Transfer
1 performed? —■ Case Diagnostic
Go to Step 2 System Check

1. Connect a Scan Tool.

2. Turn the ignition to RUN, engine OFF.
2 3. Use the Scan Tool in order to command the Service —
Indicator On.
Does the Service Indicator turn On? Go to Step 11 Go to Step 3
1. Turn the ignition to RUN, engine OFF.
2. Disconnect both connectors at the transfer case shift
control module.
3 3. Connect a fused jumper wire from the at the transfer —
case shift control module harness connector C1
terminal E2 to ground.
Does the Service Indicator turn On? Go to Step 11 Go to Step 4
1. Disconnect the connector at the Instrument cluster.
2. Connect a Scan Tool Digital Multimeter DMM
between the instrument cluster harness connector
4 terminal 24 and transfer case shift control module 0 -5 0
harness connector C1 terminal E2 and measure the
resistance.
Is the resistance within the specified values? Go to Step 5 Go to Step 8
Connect a Scan Tool DMM between the instrument cluster
5 harness connector terminal 22 and ground. 9-14 V
Is the voltage reading within the specified values? Go to Step 6 Go to Step 9
Inspect the Service Indicator lamp bulb for open.
6 —■
Is the Service Indicator lamp bulb for open? Go to Step 10 Go to Step 7
Service Instrument Cluster for an open condition.
7 — —
Is the action complete? Go to Step 12
Repair open in CKT 1567. Refer to Wiring Repairs in
8 Electrical Diagnostics. — —
Is the repair complete? Go to Step 12
Repair open in CKT 39. Refer to Wiring Repairs in Wiring
9 Systems. — —
Is the repair complete? Go to Step 12
Replace the Service Indicator lamp bulb. Refer to
Instrument Cluster Lamp Replacement in the instrument
10 — —
cluster.
Is the repair complete? Go to Step 12
Replace the transfer case shift control module. Refer to
Transfer Case Control Module Replacement
11 (Automatic 4WD). — —
Is the action complete? Go to Step 12
1. Ensure the ignition is OFF.
2. Properly mount and reconnect all previously
12 disconnected ATC components. — —
Have all the ATC components been reconnected and
properly mounted? Go to Step 13
Clear all ATC DTCs. Go to Transfer
13 Have all the ATC DTCs been cleared? — Case Diagnostic —
System Check
 Repair instructio ns
Oil Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to V e h ic le
L if t in g C a u t i o n in General Information.
2. Place a container under the drain plug in order to
catch the oil.
3. Remove the fill plug.
4. Remove the drain plug. Allow the oil to drain.
Installation Procedure
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
1. Install the drain plug.
Tighten
• Tighten the New Venture Gear drain plugs to
47 N-m (35 Ib ft).
• Tighten the Borg-Warner drain plugs to
25 N-m (18 Ib ft).
2. Install the transfer case oil. Refer to A p p r o x i m a t e
F lu id C a p a c itie s .
3. Fill the transfer case until the oil level is at the
bottom of the oil fill plug hole.
4. Install the fill plug.
Tighten
• Tighten the New Venture Gear drain plugs to
47 N-m (35 Ib ft).
• Tighten the Borg-Warner drain plugs to
25 N-m (181b ft).
5. Lower the vehicle.

Shield Replacement
Removal Procedure
1. Raise and support the vehicle.
2. Remove the four bolts and the nuts securing the
transfer case shield to the frame.
3. Remove the shield from the frame.

175368
Installation Procedure
1. Install the shield to the frame.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the four bolts and the nuts securing the
transfer case shield to the frame.
Tighten
Tighten the bolts and the nuts to 35 N-m (26 Ib ft).
3. Lower the vehicle.

175388

Transfer Case Output Shaft Seal

Replacement (New Venture)
Removal Procedure
1. Raise the vehicle. Refer to L if t in g a n d J a c k i n g t h e
V e h i c l e in General Information.
2. Remove the front or the rear propeller shaft, Refer
to P r o p e l l e r S h a f t R e p l a c e m e n t ( F r o n t A x l e - A ll
E x c e p t N P 8 ) or P r o p e l l e r S h a f t R e p l a c e m e n t
( S y s t e m B a l a n c e d A s s e m b l y ) in Propeller Shaft.
3. Remove the propeller shaft yoke nut and the flat
washers.
4. The yoke nut and the flat washers are not used at
the rear on some models.
5. Remove the propeller shaft yoke.
6. Remove the transfer case shield. Refer to S h i e l d
R e p la c e m e n t.
7. Remove the seal.
• Use a screwdriver in order to remove the seal.
• Do not damage the sealing bore.

175414
 Installation Procedure
Tools Required
J29162
1. Install the seal.
1.1. Lubricate the seal lips with petroleum jelly
or with transmission oil.
1.2. Install the seal using the J 33843
1.3. For all of the vehicles except the K30 with
dual rear wheels, install the New Venture
Gear transfer case.
2. Install the transfer case shield. Refer to S h i e l d
R e p la c e m e n t.
3. Install the propeller shaft yoke.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
4. Install the flat washers and the nut, if used.
Tighten
Tighten the New Venture Gear propeller shaft
yoke nuts to 149 N-m (110 Ib ft).
5. Install the propeller shaft.
• Check the transfer case oil level and add oil as
necessary. Refer to A p p r o x i m a t e F l u i d
C a p a c itie s .
• Lower the vehicle.

Transfer Case Replacement

(Auto Four Wheel Drive )
Removal Procedure
1. Raise and support the vehicle. Refer to L if t in g a n d
J a c k i n g t h e V e h i c l e in General Information.
2. Remove the transfer case shield. Refer to S h i e l d
R e p la c e m e n t.
3. Remove the front propeller shaft. Refer to
P r o p e lle r S h a f t R e p la c e m e n t - T w o -P ie c e .
4 . Remove the rear propeller shaft. Refer to P r o p e l l e r
S h a f t R e p la c e m e n t ( S y s te m B a la n c e d A s s e m b ly ).
5. Disconnect the vehicle speed sensor electrical
connector.
6. Disconnect the wiring harness from the
transfer case.

175384
7. Remove the transfer case motor/encoder.
Support the transfer case with a jack.

8. Remove the bolts securing the transfer

the transmission adapter.
9. Remove the gasket.

10. Discard the gasket.

Installation Procedure
1. Instal l a new gasket to the transmission. Use a
gasket sealer in order to hol d the gasket in place.

2. Install the transfer case to the transmission

adapter.

N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and

Notices.
3. Install the bolts that secure the transfer case to
the transmission adapter.
Tighten
Tighten the bolts to 45 N-m (33 Ib ft).
4. Install the transfer case motor/encoder.
5. Install the electrical connectors and the wiring,
harness to the transfer case with the new
straps.
6. Install the rear propeller shaft. Refer to P r o p e l l e r
S h a f t R e p la c e m e n t ( S y s t e m B a la n c e d A s s e m b ly ).
7. Remove the jack from the transfer case. '
8. Install the front propeller shaft. Refer to P r o p e l l e r
S h a ft R e p la c e m e n t (F r o n t A x le - A ll E x c e p t N P 8 ).
9. Install the transfer case shield. Refer to
S h ie ld R e p la c e m e n t
• Check the transfer case lubricant level. Add oil
as necessary. Refer to A p p r o x i m a t e F l u i d
C a p a c itie s .
• Lower the vehicle.

165643

M otor/Encoder R eplacem ent

(Autom atic 4W D)
Removal Procedure
1. Remove the transfer case shield. Refer to Shield
Replacement.
2. Remove the transfer case wiring harness
connectors from the motor/encoder.

177160

3. Remove three bolts securing the motor/encoder

gasket and motor/encoder to the transfer case.

165625
 Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install three bolts securing the motor/encoder
gasket and motor/encoder to the transfer case.
Tighten
Tighten the motor/encoder bolts to
25 N-m (18 Ibft).
• Remove all gasket material remaining from the
motor/encoder.
• Ensure the motor/encoder aligns properly with
the transfer case interior shifting components.
• Align the motor/encoder mating surface detent
with the transfer case mating surface detent.

165625

2. Install the transfer case wiring harness connector

to the motor/encoder.
3. Install the transfer case shield. Refer to Shield
Replacement.

Transfer Case Driver Control Switch

R eplacem ent (Autom atic 4W D)
Removal Procedure
1. Remove the automatic transfer case switch from
the instrument panel.
• Pull the tabs on the rear of the switch in.
• Pull the switch straight out from the panel.
2. Remove the electrical connector from the
automatic transfer case switch.
Installation Procedure
1. Install the electrical connector to the automatic
transfer case switch.
2. Install the automatic transfer case switch into the
instrument panel.
3. Ensure the automatic transfer case switch locks
into the instrument panel.
Transfer Case Control M odule
R eplacem ent (Autom atic 4W D)
Removal Procedure
1. Remove the lower instrument panel trim.
2. Remove the two screws securing the auto transfer
case control module to the bracket.
The bracket is mounted on the l/P reinforcement.
3. Remove the electrical connector from the
auto transfer case control module.

Installation Procedure
1. Install the electrical connector to the auto transfer
case control module.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the two screws securing the auto transfer
case control module to the bracket.
T ig h te n
Tighten the transfer case control module screws
to 8 N-m (71 Ib ft).
3. Install the lower instrument panel trim.

Speed Sensor Replacem ent

(Front Speed Sensor Replacem ent)
Removal Procedure
1. Remove the electrical connector from the speed
sensor.
2. Remove the front speed sensor from the
transfer case.

163707
 Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the front speed sensor into the
transfer case.
T ig h te n
Tighten the front speed sensor to
31 N-m (23 Ibft).
2. Install the electrical connector to the speed
sensor.

Speed Sensor Replacem ent

(R ear Speed Sensor Replacem ent)
Removal Procedure
1. Remove the two electrical connectors from the
two rear speed sensors.
2. Remove the two rear speed sensors from the
transfer case.

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the two rear speed sensors to the
transfer case.
Tighten
Tighten the rear speed sensors to
31 N-m (23 Ibft).
2 . Install the two electrical connectors to the two rear
speed sensors.

163714
Descriptio n and Operation
Transfer Case C ircuit Description Transfer Case Speed Sensors
There are three speed sensors on the automatic
Transfer Case Shift Control Module transfer case (ATC), two on the rear output shaft and
The transfer case shift control module uses the one on the front output shaft. Each speed sensor
VIN information for calculations that are required for is a permanent magnet (PM) generator. The PM
the different calibrations used based on axle ratio, generator produces a pulsing AC voltage. The AC
transmission, tire size, and engine. The system does voltage level and number of pulses increases as speed
not know which calibration to use without this increases.
information.
V e h ic le S p e e d S e n s o r
The direct battery supply line (CKT 1640) provides the
power to the module and motor circuitry. One of the two on the rear output shaft is the vehicle
speed sensor (VSS) input to the powertrain control
Transfer Case Encoder Motor module (PCM). The PCM sends this information to the
The transfer case encoder motor consists of a transfer case shift control module via the Class 2
permanent magnet (PM) DC motor and gear reduction Serial Data bus.
assembly. It is located on the left hand side (drivers R e a r P ro p s h a ft S p e e d S e n s o r
side) of the transfer case. When activated it turns
the sector shaft of the transfer case (clockwise The automatic transfer case control module converts
or counter clockwise) to shift the transfer case. The the pulsating AC voltage from the rear transfer
encoder motor is controlled with a pulse width case speed sensor to a rear propshaft speed in RPM
modulated (PWM) circuit within the transfer case shift to be used for calculations. The rear propshaft
control module. This circuit consists of a driver on speed can be displayed with a scan tool.
both the Motor A and Motor B circuits. The encoder F ro n t P ro p s h a ft S p e e d S e n s o r
motor is bi-directional to allow the motor to shift
The transfer case shift control module converts the
the transfer case from 2HI or 4HI to neutral and 4LO pulsating AC voltage from the front transfer case
positions. speed sensor to front propshaft speed in RPM to be
Transfer Case Encoder used for calculations, and to monitor the difference
between the front and rear sensor speed. It is
The encoder is mounted to the transfer case encoder
also used in the AUTO (Adapt) mode of operation to
motor assembly and is replaced as an assembly.
determine the amount of slip and the percent of torque
The encoder converts the sector shaft position
to apply to the front axle. The front propshaft speed
(representing a mode or range) into electrical signals
can be displayed with a scan tool.
inputs to the automatic transfer case control module.
The module can detect what position the transfer case SERVICE indicator (4WD/AWD) Lamp
is in by monitoring the 4 encoder channels (P, A, B, The SERVICE indicator (4WD/AWD) lamp is an
and C). These inputs translates into AUTO, 2H, integral part of the cluster and cannot be serviced
4H, Neutral, and 4L or in transition between gears. separately. This lamp is used to inform the driver of the
Transfer Case Motor Lock vehicle of malfunctions within the automatic transfer
case (ATC) system. The SERVICE indicator
The transfer case motor lock is used to provide a 2H,
(4WD/AWD) lamp is controlled by the transfer case
4H, and 4L lock-up feature. When the lock circuit
shift control module via CKT 1567.
is energized, the transfer case encoder motor
is allowed to turn. When the transfer case is placed
2H, 4H, or 4L the motor lock circuit has no power Special Tools and Equipment
provided to it and the lock is applied. This assures that Illustration Tool Number/Description
the transfer case remains in the current gear position.
When AUTO is selected the motor lock remains
applied until an adaptive mode (torque is applied to
the front propshaft) is required. During an adaptive
mode the motor lock circuit is energized and the motor
lock is released, enabling the encoder motor to turn
and apply torque to the front propshaft. J 29162
Output Shaft Seal Installer

404841
BLANK