Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSGMC1992JIMMY BASE, 2D UTILITY, 4.3 W, RWD, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONTRANSFER CASETRANSFER CASE - OVERHAUL - NEW VENTURE 233TRANSFER CASE DISASSEMBLY
1992 GMC Jimmy Base, 2D Utility, 4.3 W, RWD, Automatic
Transfer Case Disassembly
1992 GMC Jimmy Base, 2D Utility, 4.3 W, RWD, AutomaticSECTION Transfer Case Disassembly
NOTE:
See Figure for exploded view of transfer case.
- Remove front output yoke. Discard lock nut. Remove encoder motor, vacuum switch and speed sensor. Remove extension housing and rear output bearing retainer snap ring. Using 2 screwdrivers under each tab, remove pump retainer housing. Remove speedometer tone wheel from mainshaft. Remove rear case and oil pump as an assembly.
- Remove pump pick-up screen and tube from rear case. See Fig 1. Remove oil pump. Remove "O" ring from oil pump and discard. Mar k pump housing position for reassembly purposes. Separate oil pump halves. Note gear positions for reassembly reference and remove them from housing.
- Remove mode shift fork spring. Using a soft hammer, tap front output shaft upward and remove with drive chain as an assembly. Remove mainshaft, mode fork and shift rail as an assembly. Remove mode fork and shift rail from synchronizer sleeve.
- Mark synchronizer sleeve position for reassembly purposes. Remove synchronizer sleeve from mainshaft. Remove synchronizer hub snap ring. Remove synchronizer hub, synchronizer ring and drive sprocket. Slide range fork pin out of shift sector.
- Remove range shift fork and range shift hub as an assembly. Remove shift sector, bushing and "O" ring. Remove shift detent pin, spring and plug. Remove front bearing retainer. Remove input gear snap ring.
- Press input gear and planetary carrier assembly from annulus gear. Remove planetary carrier snap ring. Remove input gear snap ring, thrust washers and input gear from planetary carrier.
- Remove all oil seals. Remove magnet from front case. Remove front bearing snap ring. Using a plastic hammer, remove front bearing. Press input gear bearing from front case.
- Using slide hammer and internal puller, remove input gear pilot bearing. Press bearings from drive sprocket. Using internal puller and slide hammer, remove output shaft rear bearing.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.