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Service 4WD Message Illuminated, DTC C0327 Set, New Service P/N for Transfer Case Encoder Motor Assembly (Replace Transfer Case Encoder Motor, Install New D-Ring Seal, Reprogram Transfer Case Module) (09-04-21-005D)

Publication date: 2011-01-05
Reference number: 09-04-21-005D
Supersedes refnos: 09-04-21-005, 09-04-21-005A, 09-04-21-005B, 09-04-21-005C

Service 4WD Message Illuminated, DTC C0327 Set, New Service P/N for Transfer Case Encoder Motor Assembly (Replace Transfer Case Encoder Motor, Install New D-Ring Seal, Reprogram Transfer Case Module)

Service 4WD Message Illuminated, DTC C0327 Set, New Service P/N for Transfer Case Encoder Motor Assembly (Replace Transfer Case Encoder Motor, Install New D-Ring Seal, Reprogram Transfer Case Module)

TECHNICAL SERVICE BULLETIN

Reference Number(s): 09-04-21-005D, Date of Issue:  January 05, 2011
Affected Model(s): 2006-2010 HUMMER H3, SUT; Equipped with RPO NR4 or NR6 Transfer Case
Supercedes: This bulletin is being revised to update the repair procedure. Please discard Corporate Bulletin Number 09-04-21-005C (Section 04 - Driveline/Axle).
Superceded Bulletin(s): 09-04-21-005C, Date of Issue:  November 23, 2010

Condition

Some customers may comment that the Service 4WD message is illuminated. Upon further investigation, a technician may find DTC C0327 - Encoder Circuit Malfunction set as Current or in History.

Cause

This condition may be caused by the transfer case shift control module receiving an invalid reading from the transfer case encoder motor. The invalid reading may have been generated as a result of contamination entering the transfer case encoder motor. The transfer case shift control module sets DTC C0327 when it detects a high voltage when a low voltage is expected or a low voltage when a high voltage is expected or an invalid sequence during a transfer case shift.

Correction

Technicians are to perform the following procedures to correct this condition depending on the model being serviced. Separate procedures are provided for both the V8 and I-5 models; however both procedures involve the following steps:

  1. Remove and replace the transfer case encoder motor with a revised design and  install an updated seal as required using the proper dedicated procedure below.
  2. A revised calibration has been released to calibrate to the revised motor. Reprogram the transfer case module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI.

    When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version.

    When using a Tech 2® for reprogramming, ensure that it is updated with the latest software version.

    During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics® PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming.

5 Cylinder Engine Equipped - Transfer Case Actuator Motor Replacement

The following instructions pertain to vehicles with I-5 engines only.

    Fig 1: Electrical Connector (2) Retaining Clip (1)
    GM2545300Courtesy of GENERAL MOTORS CORP.
  1. Separate the electrical connector (2) from the retaining clip (1). The retaining clip is to remain attached to the transfer case and is to be used during installation.
    2. Fig 2: Transfer Case Actuator Motor (3)
    GM2545277Courtesy of GENERAL MOTORS CORP.
  2. Remove the motor retaining bolts (1 and 2).
  3. Remove the motor assembly (3).
    4. Fig 3: Nuts (1) & Bracket (2)
    GM2545280Courtesy of GENERAL MOTORS CORP.
  4. Remove the nuts (1) and bracket (2) from the motor (3).
  5. Retain the nuts and bracket to be transferred onto the replacement motor.
  6. Remove the nuts and bracket from the replacement motor, P/N 89059688, and transfer the original nuts and bracket to the replacement motor. DO NOT TIGHTEN THE NUTS AT THIS TIME.
    7. Fig 4: D-Ring Seal, P/N 19209788 (12)
    GM2545287Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A transfer case encoder motor D-ring seal, P/N 19209788, must be installed when replacing the motor. If the transfer case is of an earlier design and the seal is not present, install the requested encoder motor seal.
  7. Install a new D-ring seal (12). If not originally equipped, add the seal during installation.
    8. Fig 5: Transfer Case Actuator Motor (3)
    GM2545277Courtesy of GENERAL MOTORS CORP.
  8. Install the motor (3) and bolts (1 and 2) to the transfer case.

    Tighten:   Tighten the BRACKET nuts to 10 N.m (89 lb in).

    Tighten:   Tighten the bolts to 10 N.m (89 lb in).

    9. Fig 6: Tie Strap, P/N 12355066 (2)
    GM2545285Courtesy of GENERAL MOTORS CORP.
  9. Install a tie strap, P/N 12355066 (2), through the opening of the clip (1) and around the harness connector (3).
  10. Position the harness connector against the clip.
    11. Fig 7: Secured Strap (1)
    GM2545281Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not secure the tie strap directly to the harness wires.
  11. Secure the strap (1) around the harness connector and tighten until snug.
  12. Reprogram the transfer case module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB.

5.3L 8 Cylinder Engine Equipped - Transfer Case Actuator Motor Replacement

The following instructions pertain to vehicles with V-8 engines only.

    Fig 8: Electrical Connector (1) Retaining Clip (2)
    GM2545279Courtesy of GENERAL MOTORS CORP.
  1. Separate the electrical connector (1) from the retaining clip (2). The retaining clip is to remain attached to the transfer case and is to be used during installation.
    2. Fig 9: Transfer Case Actuator Motor (3)
    GM2545277Courtesy of GENERAL MOTORS CORP.
  2. Remove the motor retaining bolts (1 and 2).
    3. Fig 10: Nuts (1) & Bracket (2)
    GM2545280Courtesy of GENERAL MOTORS CORP.
  3. Remove the motor assembly (3).
  4. Remove the nuts (1) and bracket (2) from the motor (3).
  5. Retain the nuts and bracket to be transferred onto the replacement motor.
  6. Remove the nuts and bracket from replacement motor, P/N 89059688, and transfer the original nuts and bracket to the replacement motor. DO NOT TIGHTEN THE NUTS AT THIS TIME.
    7. Fig 11: D-Ring Seal, P/N 19209788 (12)
    GM2545287Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A transfer case encoder motor D-ring seal, P/N 19209788 must be installed when replacing the motor. If the transfer case is of an earlier design (including 2010 LH8 and 2011 LH9 NR4 service replacement assemblies, P/N 24243593 / 24247880), it may be necessary to remove the motor to inspect and confirm the seal is present.
  7. Install a new D-ring seal (12). If not originally equipped, add the seal during installation.
    8. Fig 12: Transfer Case Actuator Motor (3)
    GM2545277Courtesy of GENERAL MOTORS CORP.
  8. Install the motor (3) and bolts (1 and 2) to the transfer case.

    Tighten:   Tighten the BRACKET nuts to 10 N.m (89 lb in).

    Tighten:   Tighten the bolts to 10 N.m (89 lb in).

    9. Fig 13: Electrical Connector (1) Retaining Clip (2)
    GM2545279Courtesy of GENERAL MOTORS CORP.
  9. Install the connector (1) to the clip (2).
  10. Reprogram the transfer case module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB.

Parts Information

Parts Information

Part Number Description
19209788 SEAL, TRANSFER CASE FOUR WHL DRV ACTR
89059688 ACTUATOR, TRANSFER CASE FOUR WHL DRV
12355066 TIE STRAP, PLASTIC (BLACK)

Warranty Information

For vehicles repaired under warranty, use:

Warranty Information

Labor Operation Description Labor Time
K4126 Transfer Case Two/Four Wheel Drive Actuator Replacement Use Published Labor Operation Time
K4121 Transfer Case Module Reprogramming with SPS 0.4 hr
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