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Home >> Cadillac >> 2013 >> XTS AWD V6-3.6L >> Repair and Diagnosis >> Transmission and Drivetrain >> Transfer Case >> Service and Repair >> Overhaul >> Transfer Case Assemble

Transfer Case Assemble




Transfer Case Assemble

Front Wheel Drive Intermediate Shaft Seal Installation

Special Tools

* DT-305-1/KM-305-1 - Remover/Installer

* DT-49953 - Seal Installer

For equivalent regional tools, refer to Special Tools Tools and Equipment.





Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 - installer (2) with DT-305-1/KM-305-1 - remover/installer (1).

Input Shaft Bearing Retainer Rear Seal Installation

Special Tools

* DT-305-1/KM-305-1 - Remover/Installer

* DT-49951 - Seal Installer

For equivalent regional tools, refer to Special Tools Tools and Equipment

1. Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to clean the threads of old threadlocking material.

2. Spray thread cleaner into the holes. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid - Transfer Case.

Warning

Wear safety glasses when using compressed air in order to prevent eye injury.

3. Clean the transfer case housing and rear extension housing bolt holes with compressed air.





Note: Install the NEW seal with the notched surface of the seal facing away from the installer tool.

4. Install the NEW input shaft rear seal (1) to the rear extension housing using the DT-49951 - installer (2) and DT-305-1/KM-305-1 - remover/installer (3).

Idler Gear Shaft Rear Seal Installation





Install a NEW idler gear shaft rear seal (1) to the rear extension housing. - RPO MXE

Idler Gear Shaft Front Seal Installation





Install a NEW transfer case idler gear shaft front seal (1) to transfer case. - RPO MXE

Input Shaft Bearing Retainer Front Seals Installation

Special Tools

* DT-305-1/KM-305-1 - Remover/Installer

* DT-49952 - Installer

For equivalent regional tools, refer to Special Tools Tools and Equipment.





Note: Install the NEW seal with the notched surface of the seal facing the installer tool.

1. Install the input shaft front (inner) seal (1), to the transfer case using the DT-49952 - installer (2) and DT-305-1/KM-305-1 - remover/installer (3).





Note: Install the NEW seal with the notched surface of the seal facing the installer tool.

2. Install the input shaft front (outer) seal (1), to the transfer case using the DT-49952 - installer (2) and DT-305-1/KM-305-1 - remover/installer (3).

Input Shaft and Idler Gear Installation





Caution:
Cover the splines of the input shaft to prevent damage to the input shaft oil seals during installation.

Install input shaft (1) and idler gear (2).

Rear Extension Housing Installation - RPO MXE





1. Install the idler gear shaft (1) to the rear extension housing - RPO MXE.




2. Install a NEW rear extension housing-to-transfer case seal (1).




3. Install the rear extension housing (1) and idler gear shaft to the transfer case housing. Position the idler gear shaft into the center opening of the idler gear.





Caution: Refer to Fastener Caution Fastener Caution.

4. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (1). Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid - Transfer Case.

5. Install the NEW transfer case-to-rear extension housing bolts (1).

1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft).

2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.

Rear Extension Housing Installation - RPO MH4





1. Install a NEW rear extension housing-to-transfer case seal (1).

2. Install the rear extension housing onto the transfer case housing.





Caution: Refer to Fastener Caution Fastener Caution.

3. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid - Transfer Case.

4. Install the NEW transfer case-to-rear extension housing bolts (1).

1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft).

2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 130 degrees.

Rear Output Shaft Seal Installation

Special Tools

* DT-305-1/KM-305-1 - Remover/Installer

* DT-49954-A - Seal Installer

For equivalent regional special tools, refer to Special Tools Tools and Equipment.





Install the rear output shaft seal (3), using the DT-49954-A - installer (2) and DT-305-1/KM-305-1 - remover/installer (1).

Front Wheel Drive Intermediate Shaft Bearing Installation

Special Tools

DT-48076 - Bearing Installer

For equivalent regional tools, refer to Special Tools Tools and Equipment.




1. Press on the intermediate shaft bearing (2) onto the intermediate shaft (3), using DT-48076 - installer (1) and a hydraulic press.




2. Install the transfer case intermediate shaft bearing retaining ring (2) to intermediate shaft (1), using suitable pliers.




3. Install the second design intermediate shaft O-ring (3), as required. Refer to New Product Information Description and Operation for additional information.

Front Wheel Drive Intermediate Shaft Installation

Special Tools

* DT-113-2-A - Holder

* DT-622-A - Transmission Bracket

* DT-48076 - Bearing Installer

* DT-49104 - Protective Collar

For equivalent regional tools, refer to Special Tools Tools and Equipment.




1. Install the DT-49104 - protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft using the DT-48076 - installer (3) and a rubber mallet.

2. Remove the DT-49104 - protective collar (1).




3. Apply grease to the output splines (1) of the intermediate shaft. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid - Transfer Case.





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.




5. Install the first design dirt deflector (1) using the DT-48076 - installer. Refer to New Product Information Description and Operation for additional information.




6. Install the second design front wheel drive intermediate shaft dirt deflector (1) - model dependant using the DT 50768 seal installer (2) and J 8092 driver handle (3). Refer to New Product Information Description and Operation for additional information.

Locating Bushing Installation





Install the transfer case locating bushing (1) as required using a rubber mallet-RPO MXE.

Transfer Case-to-Transmission Seal Installation





Install the NEW transfer case-to-transmission seal (1).

Transfer Case Vent Installation




1. Apply sealant to the threads of the vent hose connector. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Fluid - Transfer Case.

2. Install the transfer case vent hose connector (1) and tighten to 25 Nm (18 lb ft).

Oil Drain Plug Installation





Caution: Refer to Fastener Caution Fastener Caution.

Install a NEW oil drain plug (1) and tighten to 40 Nm (30 lb ft).

Oil Fill Plug Installation




1. Install a NEW transfer case oil fill plug (1).

2. Once the transfer case has been filled with oil, tighten the oil fill plug to 40 Nm (30 lb ft).




3. Remove the transfer case (3) from DT-622-A - bracket (2) and DT-113-2-A - holder (1).

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