Transfer case disassembly

[turbottime]

Hello all, my 05 Envoy transfer case would not shift, tried a new encoder motor, same thing, binding.
Have it on the bench, trying to remove the output shaft to have a look at the shift mech,
cant seem to figure how to get it out, any help appreciated.

 

[Mooseman]

I have this manual for the transfer case. Hope it helps. Most of the time, when we have problems with them, we just grab a junk yard unit.

 

[turbottime]

Wow, thanks, great manual, will pick up a wrecker unit if I cant fix this, I'm stubborn, try to fix everything

 

[HARDTRAILZ]

Good Luck and try to post up what you can to help the next guy going after one!

 

[Sparky]

I like fixing vs replacing stuff when I can too. Satisfying... even if the end result took 10x longer and cost as much as replacing lol.

 

[Blckshdw]

I like fixing vs replacing stuff when I can too. Satisfying...

...even if the end result took 10x longer and cost as much as replacing lol.

 

[turbottime]

Buddy brought puller over, pressure plate bearing part#12 dissolved .
Should be able to get this going again

 

[turbottime]

Those other pics were not clear

 

[Mooseman]

Just out of curiosity, how was the maintenance on it prior to the meltdown? Was the fluid changed every 50K miles?

 

[turbottime]

Poorly maintained, bought this awhile ago , needed a lot of repairs. I don't think the tc fluid had ever been changed, came out pure black, probably caused that bearing to fail.

Has 150000 hard miles on it

 

[turbottime]

Update, back together for a few weeks, working good, replaced parts 11,12,13
Thought I would post a pic of a easy tool to make to install the speed sensor gear.Just a piece of exhaust tubing, plate with a 1/4" hole in it, piece of 1/4-20 unc threaded rod and nut.

 

[rtliquid]

I have this manual for the transfer case. Hope it helps. Most of the time, when we have problems with them, we just grab a junk yard unit.

Mooseman, do you know what years are interchangeable? I have an '04 LS/LT 4.2.

 

[Mooseman]

I believe all years are the same. Just make sure it's the 4x4 version and not the AWD type. Do a search on car-part.com and you'll see all the years that are compatible in the search results.