Repair Instructions - Off Vehicle

Document ID: 1914113 Page 1 of 7
| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

2009 Cadillac CTS
Repair Instructions - Off Vehicle | Document ID: 1914113
Transfer Case Disassemble

Table 1: Dampener and Rear Output Flange Removal
Table 2: Vent Assembly, Drain Plug, Fill Plug, and Temperature Sensor Removal
Table 3: Front Output Shaft Removal
Table 4: Cover, Apply Cam, and Clutch Pack Removal
Table 5: Chain, Sprockets, Oil Pump, and Input Shaft Removal
Table 6: Coil Removal
Table 7: Chain Snubber and Vent Baffle Removal
Dampener and Rear Output Flange Removal
Dampener and Rear Output Flange Removal

Callout Component Name
1 Transfer Case Vibration Dampener Bolt
2 Transfer Case Vibration Dampener
Transfer Case Rear Output Shaft Flange Nut
3 Special Tools
© 2010 General Motors Corporation. All rights reserved.
http://localhost:9001/si/showDoc.do?docSyskey=1914113&pubCellSyskey=163965&pub... 10/4/2010
DT-48847 Pinion Flange Holder

4 Transfer Case Rear Output Shaft Thrust Washer
5 Transfer Case Rear Output Shaft Flange O-Ring Seal
Transfer Case Rear Output Shaft Flange Assembly
6
Tip
Use a 2 Jaw Puller to remove the flange.
Transfer Case Rear Output Shaft Seal Dirt Deflector
7
Tip
Remove only if damaged.
Vent Assembly, Drain Plug, Fill Plug, and Temperature Sensor

Removal
Vent Assembly, Drain Plug, Fill Plug, and Temperature Sensor Removal
Transfer Case Vent Assembly
1
Tip
Remove only if damaged or blocked.
2 Transfer Case Oil Fill Plug
3 Transfer Case Oil Drain Plug - Magnetic
4 Transfer Case Temperature Sensor Assembly
Front Output Shaft Removal
Front Output Shaft Removal

1 Transfer Case Front Output Shaft Hole Plug
2 Transfer Case O-Ring Seal
3 Transfer Case Front Output Shaft Bearing Retaining Ring
4 Transfer Case Front Output Shaft
Transfer Case Front Output Shaft Seal Dirt Deflector
5
Tip
Remove only if damaged.
Cover, Apply Cam, and Clutch Pack Removal
Cover, Apply Cam, and Clutch Pack Removal

1 Transfer Case Half Bolt
2 Transfer Case - Rear Half
3 Transfer Case Thrust Washer
4 Transfer Case Thrust Bearing
5 Transfer Case Rotor Assembly
6 Transfer Case Balls
7 Transfer Case Apply Cam
8 Transfer Case Wave Spring
9 Transfer Case Snap Ring
10 Clutch Pack Assembly
11 Transfer Case Front Output Shaft Drive Sprocket Spacer
Chain, Sprockets, Oil Pump, and Input Shaft Removal
Chain, Sprockets, Oil Pump, and Input Shaft Removal

Transfer Case Front Output Shaft Drive Chain Assembly
Procedure:
Remove the drive chain assembly, transfer case front output shaft drive sprocket,
1 and the transfer case front output shaft driven sprocket simultaneously.
Tip
Note the orientation of the single blue link on the chain. The link should be facing
upward. It is important to re-assemble the chain in the same orientation that it was
found.
2 Transfer Case Front Output Shaft Drive Sprocket Thrust Washer
3 Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly
Transfer Case Oil Pump Assembly
5
Tip
Loosen the pump suction hose clamp bolt.
6 Transfer Case Input Shaft Assembly
7 Transfer Case Front Output Shaft Driven Sprocket Spacer
Coil Removal
Coil Removal
Preliminary Procedure
Remove the coil only if required, due to damage or leakage.

1 Transfer Case Coil Nut (Qty: 3)
2 Transfer Case Clutch Coil Harness Protector
Transfer Case Clip
3
Tip
The clip must be disassembled in order to remove the coil.
4 Transfer Case Coil Connector Assembly
5 Transfer Case Coil Assembly
Chain Snubber and Vent Baffle Removal
Chain Snubber and Vent Baffle Removal

1 Transfer Case Front Output Shaft Drive Chain Snubber Bolt (Qty: 2)
2 Transfer Case Front Output Shaft Drive Chain Snubber
3 Transfer Case Vent Baffle Bolt
4 Transfer Case Vent Baffle

2009 Cadillac CTS
Transfer Case Cleaning and Inspection

Table 1: Transfer Case and Cover Cleaning and Inspection
Table 2: Clutch Components Cleaning and Inspection
Table 3: Chain, Sprockets, and Snubber Cleaning and Inspection
Table 4: Input Shaft and Front Output Shaft Cleaning and Inspection
Table 5: Coil Assembly Cleaning and Inspection
Table 6: Oil Pump and Suction Pipe Assembly Cleaning and Inspection
Transfer Case and Cover Cleaning and Inspection
Transfer Case and Cover Cleaning and Inspection

Caution: Refer to Machined Surface Damage Caution in the Preface section.
Preliminary Procedures
1. Inspect all components or sub-components and perform any repair procedure

necessary to fix the damage.
2. Remove the sealer from the case sealing surfaces.
3. Clean the case and cover in cleaning solvent and air dry.
4. Inspect for cracks, broken areas, or other damage. Repair small scratches on the
sealing surfaces with light sanding.
1 Transfer Case - Rear Half
2 Transfer Case - Front Half
Transfer Case Bearing Race Bores
3
Tip
Replace the rear case or front case if a race has spun or cracks are detected.
Clutch Components Cleaning and Inspection
Clutch Components Cleaning and Inspection


necessary to fix the damage. The clutch pack is only available as an assembly (1-4).
2. Do not clean the clutch fiber plates in solvent. Other components may be cleaned in
solvent.
Transfer Case Clutch Pack Housing and Clutch Hub
1 Tip
Inspect the clutch housing and clutch hub for excessive wear or damage. Excessive
wear can be identified by steps in the teeth, which prevent the plates from moving
freely.
Transfer Case Friction Plate
Tip
2 • The friction plates are assembled with the lube holes aligned. This provides an
unrestricted oil path when assembled.
• Inspect the plates for worn, scored, or burnt friction material.
• Inspect the plates for flatness and warping.
Transfer Case Separator Plate
Tip
3 • The friction plates are assembled with the lube holes aligned. This provides an
unrestricted oil path when assembled.
• Inspect the plates for worn, scored, or burnt friction material.
• Inspect the plates for flatness and warping.
Transfer Case Pressure Plate
4
Tip
Inspect the plates for flatness and warping.
Transfer Case Armature
Tip
5 Small scratches or wear patterns are allowed on the armature. Deep gouges or
raised metal in armature require transfer case replacement. The armature is
assembled in the clutch pack with the rounded edges on the spline teeth towards
the pack. The armature is not serviced.
Transfer Case Clutch Pack Assembly
Tip
6 If the clutch pack assembly is replaced, a 12.7 k ohm clutch coil resistor should be
used in place of the pre-existing resistor. If the resistor is replaced due to loss or
damage without replacing the clutch pack, replace with one of the same resistance
and refer to Transfer Case Clutch Coil Resistor Replacement.
Chain, Sprockets, and Snubber Cleaning and Inspection
Chain, Sprockets, and Snubber Cleaning and Inspection

1. Clean all components in solvent and air dry.

1 Tip
Inspect the chain for loose links or pins, binding links, embedded debris, and worn
tooth surfaces.
Transfer Case Front Output Shaft Drive Sprocket
2 Tip
Inspect the sprockets for chipped teeth, embedded debris, and excessively worn
gear surfaces. Slight wear marks are normal.
Transfer Case Front Output Shaft Driven Sprocket
3 Tip
Inspect the sprockets for chipped teeth, embedded debris, and excessively worn
gear surfaces. Slight wear marks are normal.
Transfer Case Front Output Shaft Drive Chain Snubber
4
Tip
Inspect the snubber for an excessively worn or gouged lining. Slight wear marks are
normal.
Input Shaft and Front Output Shaft Cleaning and Inspection
Input Shaft and Front Output Shaft Cleaning and Inspection

1. Clean the shafts in solvent and air dry, including the input shaft oil galleries.
Transfer Case Input Shaft Assembly
Tip
1 • Inspect the bearing journals for scoring, pitting, or excessive wear.
• Do not attempt to smooth roughness in the bearing journals.
• Inspect the splines for damage or excessive wear. Witness marks are
normal.
Transfer Case Front Output Shaft
2 Tip
• Inspect the bearing journals for scoring, pitting, or excessive wear.
• Do not attempt to smooth roughness in the bearing journals.
• Inspect the splines for damage or excessive wear. Witness marks are
normal.
Coil Assembly Cleaning and Inspection
Coil Assembly Cleaning and Inspection


2. Inspect components and perform any repair procedure necessary to fix the damage.
The coil is serviced as an assembly.
Transfer Case Coil Assembly Studs
1
Tip
Inspect the studs and O-rings for damage.
Transfer Case Coil Assembly Wires
2
Tip
Inspect the wires and terminals for damage. Repair, as required.
Oil Pump and Suction Pipe Assembly Cleaning and Inspection
Oil Pump and Suction Pipe Assembly Cleaning and Inspection

1. Remove the oil pump suction hose from the screen and pump.
3. Inspect components and perform any repair procedure necessary to fix the damage.
1 Tip
• Inspect the pump for free movement. Replace the pump if it is binding.
• Do not disassemble the pump. The pump is serviced as an assembly.
Transfer Case Oil Pump Assembly Screen and Hose
2
Tip
Inspect the screen and hose for cracks, tears, or debris.

2009 Cadillac CTS
Front Output Shaft Front Bearing Replacement

Transfer Case Front Output Shaft Front Bearing
1 Tip
• Remove the bearing only if it is to be replaced.
• Use a hammer and suitable punch to remove the bearing.

2009 Cadillac CTS
Input Shaft Bearing Replacement

Transfer Case Input Shaft Bearing
1 Tip
• Use a hammer and a suitable punch to remove the bearing.

2009 Cadillac CTS
Rear Output Shaft Rear Bearing Replacement

Transfer Case Rear Output Shaft Rear Bearing
1 Tip
• Use a hammer and a suitable punch to remove the bearing.

2009 Cadillac CTS
Front Output Shaft Seal Replacement

Transfer Case Front Output Shaft Seal
Special Tools
1 • J-2619-A Slide Hammer w/ Adapter

• J 8092 Driver Handle
• J 45278 Seal Remover
• J 46268 Output Seal Installer

2009 Cadillac CTS
Input Shaft Seal Replacement

Transfer Case Input Shaft Seal
Special Tools
1 • J-2619-A Slide Hammer w/ Adapter

• J 46268 Output Seal Installer

2009 Cadillac CTS
Rear Output Shaft Seal Replacement

Rear Output Shaft Seal
Special Tools
1 • DT-48846 Output Seal Installer

• J-2619-A Slide Hammer w/Adapter

2009 Cadillac CTS
Transfer Case Assemble

Table 1: Coil Installation
Table 2: Chain Snubber and Vent Baffle Installation
Table 3: Chain, Sprockets, Oil Pump, Input Shaft, and Front Output Shaft Installation
Table 4: Apply Cam, and Clutch Pack Installation
Table 5: Case Half and Front Output Shaft Hole Plug Installation
Table 6: Dampener and Rear Output Flange Installation
Table 7: Vent Assembly, Drain Plug, Fill Plug, and Temperature Sensor Installation
Coil Installation
Coil Installation
1 Transfer Case Coil Assembly
2 Transfer Case Coil Nuts (Qty: 3)
3 Transfer Case Coil Connector Assembly
4 Transfer Case Clip
Transfer Case Clutch Coil Harness Protector
Tip
5 Install common tie wraps to secure the harness protector and seat the wire in the
wire clip.
Chain Snubber and Vent Baffle Installation
Chain Snubber and Vent Baffle Installation

1 Transfer Case Front Output Shaft Drive Chain Snubber
Transfer Case Front Output Shaft Drive Chain Snubber Bolts (Qty: 2)
Caution: Refer to Fastener Caution in the Preface section.
Tip
• Apply sealant GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to
2 the threads of the bolts.
• Before tightening the snubber bolts, push the snubber to the outside of the
case, so when assembled, the snubber is in the farthest position away from
the chain, taking up all clearance. See arrow in the illustration above.
Tighten
7 N·m (62 lb in)
3 Transfer Case Vent Baffle
Transfer Case Vent Baffle Bolt (Qty: 1)
Tip
• Apply sealant GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to
the threads of the bolts.
4 • Assemble the dowel pins into the case half, if previously removed.
Tighten
7 N·m (62 lb in)
Chain, Sprockets, Oil Pump, Input Shaft, and Front Output Shaft
Installation
Chain, Sprockets, Oil Pump, Input Shaft, and Front Output Shaft
Installation
Transfer Case Front Output Shaft Seal Dirt Deflector
1
Tip
Replace only if removed or damaged.
2 Transfer Case Front Output Shaft
3 Transfer Case Front Output Shaft Driven Sprocket Spacer
4 Transfer Case Input Shaft Assembly
Tip
• Center the gerotor gear spline inside the pump for ease of assembly.
5
• Rotate the pump alignment tab until it aligns with the alignment mark on the
case.
6 Transfer Case Oil Pump Suction Hose Clamp

Transfer Case Oil Pump Suction Hose Bolt

7
Tighten
7 N·m (62 lb in)
9 Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly
Procedure:
Install the drive chain assembly, transfer case front output shaft drive sprocket, and
the transfer case front output shaft driven sprocket simultaneously.
11
Tip
• Assemble the chain with the blue link facing up, unless noted differently
during disassembly.
• Assemble the drive sprocket with the clutch splines facing up.
• Assemble the driven sprocket with the center raised hub facing up.
Apply Cam, and Clutch Pack Installation
Apply Cam, and Clutch Pack Installation

1 Transfer Case Front Output Shaft Drive Sprocket Spacer
Transfer Case Clutch Pack Assembly and Armature
Tip
2 • Refer to Transfer Case Cleaning and Inspection Clutch Components for proper
clutch assembly.
• Inspect for the clutch hub and housing to be fully seated on the input shaft
with no gap. The snap ring will not assemble if not fully seated.
4 Transfer Case Wave Spring
Transfer Case Thrust Washer
9 Tip
Always verify that the correct thrust washer is installed for proper clutch end-play.
Replacement of internal components will alter the end-play. Refer to Four Wheel
Drive Clutch Shim Selection.
Case Half and Front Output Shaft Hole Plug Installation
Case Half and Front Output Shaft Hole Plug Installation

Transfer Case - Rear Half
1 Tip
Apply a 3.175 mm (1/8 in) bead of room temperature vulcanizing (RTV) sealant, or
equivalent, to the mating surface of the cover.
Transfer Case Half Bolt
2 Tip
The bolts are self-tapping and must be hand started. Do not use power-assisted
tools to install the bolts.
Tighten
27-35 N·m (20-26 lb in)
3 Transfer Case Location Pin - If Removed
4 Transfer Case Front Output Shaft Bearing Retaining Ring
Transfer Case O-Ring Seal
5
Tip
If the seal is removed, replace with a NEW seal.
Transfer Case Front Output Shaft Hole Plug
Tighten
6
15-20 N·m (11-14 lb ft)
Dampener and Rear Output Flange Installation
Dampener and Rear Output Flange Installation

Transfer Case Rear Output Shaft Seal Dirt Deflector
1
Tip
Replace only if removed or damaged.
2 Transfer Case Rear Output Shaft Flange Assembly
3 Transfer Case Rear Output Shaft Flange O-Ring Seal
4 Transfer Case Rear Output Shaft Thrust Washer
Transfer Case Rear Output Shaft Flange Nut
Tighten
5
305-332 N·m (225-245 lb ft)
Special Tools
DT-48847 Pinion Flange Holder

6 Transfer Case Vibration Dampener
Transfer Case Vibration Dampener Bolt
7
Tighten
27-35 N·m (20-26 lb ft)

Installation

Installation
1 Transfer Case Temperature Sensor Assembly
Transfer Case Oil Drain Plug - Magnetic
Caution: Refer to Component Fastener Tightening Caution in the Preface section.
Tip
2
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the drain plug
before installation.
Tighten
19-30 N·m (14-22 lb ft)
Transfer Case Oil Fill Plug
Tip
• Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the fill plug
before installation.
3
• Fill the transfer case with fluid. Refer to Adhesives, Fluids, Lubricants, and
Sealers and Approximate Fluid Capacities.
Tighten
19-30 N·m (14-22 lb ft)
4 Transfer Case Vent Assembly

2009 Cadillac CTS
Four Wheel Drive Clutch Shim Selection

1. The purpose of this procedure is to obtain a proper clutch travel of 0.7-1.2 mm

(0.0275-0.0472 in.) when assembled with a selective thrust washer.
2. Assemble or disassemble the internal components to the clutch pack snap ring (1).
Refer to Transfer Case Assemble Transfer Case Cover, Apply Cam, and Clutch Pack
Installation.
Transfer Case Wave Spring
2
Tip
Temporarily remove the spring (2) for selective thrust washer measurement.
Transfer Case Selective Thrust Washer
Procedure
1. Attach, screw, the DT-48553 to the input shaft until hand tight.
2. Attach the J 8001 .
3. Zero the J 8001 on the rotor assembly in the "free state" assembled position.
4. Rotate the rotor counter clockwise using moderate hand pressure until it
stops. Record this measurement.
5. The ideal thrust washer selected will create the nominal clutch travel of
0.95 mm (0.0375 in.)
6. The selective thrust washer requires verification before proceeding. Remove
the DT-48553 , install the selected thrust washer and re-measure the travel
as performed above to obtain a clutch pack travel of 0.7-1.2 mm (0.0275-
7
0.0472 in). Refer to Spacer and Shim Specifications for a list of available
thrust washer sizes.
7. Remove the J 8001 and the DT-48553 .
8. Disassemble the components to the clutch pack retaining ring (1).
9. Assemble the internal components. Refer to Transfer Case Assemble Transfer
Case Cover, Apply Cam, and Clutch Pack Installation.
Special Tools
• DT-48553 Clutch Pack Measurement Adapter

• J 8001 Dial Indicator

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Document ID: 1914113 Page 1 of 7

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Transfer Case Disassemble

Dampener and Rear Output Flange Removal

Dampener and Rear Output Flange Removal

© 2010 General Motors Corporation. All rights reserved.

DT-48847 Pinion Flange Holder

Vent Assembly, Drain Plug, Fill Plug, and Temperature Sensor

4 Transfer Case Temperature Sensor Assembly

Front Output Shaft Removal

Front Output Shaft Removal

Cover, Apply Cam, and Clutch Pack Removal

Cover, Apply Cam, and Clutch Pack Removal

Chain, Sprockets, Oil Pump, and Input Shaft Removal

Chain, Sprockets, Oil Pump, and Input Shaft Removal

Remove the coil only if required, due to damage or leakage.

Chain Snubber and Vent Baffle Removal

Chain Snubber and Vent Baffle Removal

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Transfer Case Cleaning and Inspection

Transfer Case and Cover Cleaning and Inspection

Transfer Case and Cover Cleaning and Inspection

1. Inspect all components or sub-components and perform any repair procedure

Clutch Components Cleaning and Inspection

Clutch Components Cleaning and Inspection

1. Inspect all components or sub-components and perform any repair procedure

Transfer Case Clutch Pack Housing and Clutch Hub

Chain, Sprockets, and Snubber Cleaning and Inspection

Chain, Sprockets, and Snubber Cleaning and Inspection

1. Clean all components in solvent and air dry.

Input Shaft and Front Output Shaft Cleaning and Inspection

Input Shaft and Front Output Shaft Cleaning and Inspection

Coil Assembly Cleaning and Inspection

Coil Assembly Cleaning and Inspection

1. Clean all components in solvent and air dry.

Oil Pump and Suction Pipe Assembly Cleaning and Inspection

Oil Pump and Suction Pipe Assembly Cleaning and Inspection

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Front Output Shaft Front Bearing Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Input Shaft Bearing Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Rear Output Shaft Rear Bearing Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Front Output Shaft Seal Replacement

Callout Component Name

1 • J-2619-A Slide Hammer w/ Adapter

© 2010 General Motors Corporation. All rights reserved.

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |

Input Shaft Seal Replacement

Callout Component Name

1 • J-2619-A Slide Hammer w/ Adapter

© 2010 General Motors Corporation. All rights reserved.

| CTS (VIN D) Service Manual | Transmission | Transfer Case - BW 4477 |