Transfer Case Assemble

Tools Required
• J 8092 Universal Handle
• J 37668-A Seal Installer
• J 42738 Seal Installer
• J 43484 Seal Installer

Assembly Procedure

Important

Important

1. Install the mounting studs to 1.16 inch to 1.20 inch in height (if removed).
   
   
   

   Important

   When installing the input gear bearing, make sure the printing on the bearing is facing up (toward the technician installing the bearing).

2. Using a press, install the input gear bearing.
   
   
   
3. Install the input gear bearing retaining ring.
   
   
   
4. Install the input gear
   
   
   
5. Install the input gear retaining ring.
   
   
   

   Important

   When installing the front output shaft bearing, make sure the printing on the bearing is facing up (toward the technician installing the bearing).

6. Using a press, install the front output shaft bearing.
   
   
   
7. Using a press, install the front output shaft.
   
   
   
8. Install the front output shaft retaining ring.
   
   
   
9. Install the viscous coupling.
   
   
   
10. Install the mainshaft assembly.
    
    
    

    Important

    The blue colored link must be facing up (toward the rear of the vehicle).

11. Install the drive chain and sprockets.
    
    
    
12. Install the driven sprocket retaining ring.
    
    
    
13. Install the carrier retaining ring.
    
    
    

    Important

    Make sure that the spline engages with both the sprocket and viscous coupling cover. The sun gear shoulder will bottom on the sprocket if installed correctly.

14. Install the sun gear.
    
    
    
15. Install the sun gear thrust washer.
    
    
    

    Important

    When installing the carrier assembly, a snap should be felt and heard when the carrier is properly seated.

16. Install the carrier assembly.
    
    
    
17. Install the rear output shaft in the annulus gear.
    
    
    
18. Install the annulus gear retaining ring. If the retaining ring is not fully seated and the annulus gear becomes disengaged from the rear output shaft during operation, vehicle could roll when put in park. Also, damage to the viscous coupling could occur.
    
    
    
19. Install the oil pump assembly.
    
    
    
20. Install the tone wheel retaining ring.
    
    
    

    Important

    The tone wheel should bottom on the retaining ring.

21. Using a press, install the tone wheel.
    
    
    

    Important

    Ensure that the retaining ring groove on the rear output shaft bearing is facing up (toward the rear of the vehicle).

22. Using a press, install the rear output shaft bearing.
    
    
    
23. Install the rear output shaft bearing retaining ring.
    
    
    
24. Install the rear output shaft assembly.
    
    
    
25. Install the wear clip in the rear case half.
    
    
    

    Important

    Ensure that the O-ring is in place in the oil pump.

26. Install the oil pump screen and magnet assembly.

    Important

    Ensure that both sealing surfaces on the front and rear case halves are free of any silicone sealant, dirt or cleaning solvent.

27. Apply an 1/8 in bead of RTV sealant GM P/N 12345739 or equivalent to the front case half. Excessive RTV will squeeze into the case and plug the oil pump pick up screen.
28. Align the rear case on the rear output shaft bearing.
    
    
    
29. Insert a pair of snap ring pliers in the slot.
30. Open the outer rear output shaft bearing retaining ring.

    Important

    Ensure that the rear output shaft bearing retaining ring is seated in the groove properly by prying up on the shaft on the rear output shaft assembly.

31. Lower the rear case on to the rear output shaft bearing.
32. Remove the snap ring pliers.

    Important

    Ensure that when the rear case is installed, that it is squarely seated on the alignment dowels.

33. Lower the rear case on to the alignment dowels
    
    
    

    Notice

    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important

    Ensure that the retaining bracket under the bolt is in line with the speed sensor.

34. Install the transfer case bolts. Tighten

    Tighten the retaining bolts to 31 N·m (23 lb ft)

    
    
    
    
35. Using the J 42738 , install the input gear seal.
    
    
    

    Important

    Ensure that the drain hole on the boot of the rear output shaft seal is facing down toward the ground.

36. Using the J 37668-A , install the rear output shaft seal.
    
    
    
37. Using the J 43484 (2) and the J 8092 (1) install the front output shaft seal.
    
    
    
38. Install the transfer case speed sensor. Tighten

    Tighten the transfer case speed sensor to 15 N·m (11 lb ft).

    
    
    
    

    Important

    Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case.

39. Install the drain plug. Tighten

    Tighten the drain plug to 20 N·m (15 lb ft).

    
    
    
    
40. Install the fill plug. Tighten

    Tighten the fill plug to 20 N·m (15 lb ft).

    
    
    
    
41. Install the rubber plug.