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Gears and Cases Assembly Procedure

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    Fig 1: Installing Bearing Onto Idler Gear
    GM746878Courtesy of GENERAL MOTORS CORP.
  1. Use the J 5590  (1) and a hydraulic press in order to install the bearings onto the idler gear.
    2. Fig 2: View Of Bearing Race In Left Cover
    GM671801Courtesy of GENERAL MOTORS CORP.
  2. Use the J 44752  (1) and a hydraulic press in order to install the bearing race into the left cover. See Special Tools .
    3. Fig 3: Installing Idler Gear & Bearing Into Left Case
    GM746879Courtesy of GENERAL MOTORS CORP.
  3. Install the idler gear (2) and bearing race (1) to the left case.
    4. Fig 4: Identifying Idler Gear Long Flange Area
    GM659130Courtesy of GENERAL MOTORS CORP.
  4. Inspect the gear for proper installation. The side of the gear with the long flange area (1) should be installed to the right case side.
    5. Fig 5: View Of J 44757-1
    GM746880Courtesy of GENERAL MOTORS CORP.
  5. Install the J 44757-1  (1) to the idler gear and race.
    6. Fig 6: Installing Right Cover To Left Case
    GM746881Courtesy of GENERAL MOTORS CORP.
  6. Install the right cover (1), bolts (2) and J 44757-8 (3) to the left case.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    7. Fig 7: Measuring Gap In J 44757-1
    GM746882Courtesy of GENERAL MOTORS CORP.
  7. Using a feeler gage, measure the gap (1) in the J 44757-1  . The measured amount is the idler gear bearing shim thickness.
  8. Disassemble the right case and tools from the left case.
    9. Fig 8: Identifying Right Case Idler Gear Bearing Race
    GM659159Courtesy of GENERAL MOTORS CORP.
  9. Install the selected idler gear bearing shim (2) and bearing race (1) to the right case.
    10. Fig 9: Installing Bearing Race Into Right Case Using J 44752
    GM746885Courtesy of GENERAL MOTORS CORP.
  10. Use the J 44752  (1) and a hydraulic press in order to install the bearing race to the right case. See Special Tools .
    11. Fig 10: Identifying Right Case Bearing & Shim
    GM659159Courtesy of GENERAL MOTORS CORP.
  11. Install the driveshaft bearing (3) to the right case.
    12. Fig 11: Installing Bearing Into Right Case With J 44753
    GM746886Courtesy of GENERAL MOTORS CORP.
  12. Use the J 44753  (1) and a hydraulic press in order to install the bearing to the right case. See Special Tools .
    13. Fig 12: Expanded View Of Transaxle Side Oil Seal
    GM746889Courtesy of GENERAL MOTORS CORP.
  13. Use the J 44753  (1) to install the transaxle side oil seal (2) to the left case. See Special Tools . Install until the seal bottoms in the left case bore.
    14. Fig 13: Identifying Gear Oil Side Oil Seal
    GM746888Courtesy of GENERAL MOTORS CORP.
  14. Use the J 44753  (1) to install the oil seal-gear oil side (2) to the left case. See Special Tools . Install until the tool bottoms against the left case.
    15. Fig 14: Installing Outer Bearing Race To Left Case Using J 44908
    GM746890Courtesy of GENERAL MOTORS CORP.
  15. Use the J 44908  (1) and a hydraulic press in order to install the outer bearing race to the left case. See Special Tools .
    16. Fig 15: Installing Inner Bearing Race To Left Case Using J 44908
    GM1486694Courtesy of GENERAL MOTORS CORP.
  16. Use the J 44908  (1) and a hydraulic press in order to install the inner bearing race to the left case. See Special Tools .
    17. Fig 16: Pressing Inner Bearing Onto Drivenshaft
    GM659151Courtesy of GENERAL MOTORS CORP.
  17. Use the J 44907  (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft. See Special Tools .
    18. Fig 17: Assembling Shaft J 44757-7 Shim & Bearing To Left Case
    GM1486696Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The J 44757-7 shim is installed to create measurable end play and to assist in determining the proper size shim for bearing preload.
  18. Assemble the shaft (1), J 44757-7 shim (2) and bearing (3) to the left case.
    19. Fig 18: View Of J 5590Installing Shaft, J 44757-7 Shim, Race & Bearing To Left Case Using J 5590
    GM746891Courtesy of GENERAL MOTORS CORP.
  19. Use the J 5590  (1) and a hydraulic press in order to install the shaft, J 44757-7 shim, race and bearing to the left case.
    20. Fig 19: Installing J 44757-2, J 44757-6, J 44757-8, Bolts, Nuts & Washers
    GM746893Courtesy of GENERAL MOTORS CORP.
  20. Install the J 44757-2 (5) onto the driveshaft. Tighten until snug.
  21. Install the J 44757-6 (4), J 44757-8 (1), bolts (2) and nuts and washers (3) to the left case.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  22. Rotate the driveshaft, multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
    23. Fig 20: Using J 8001 & J 44757 Components To Determine Shim Size
    GM746894Courtesy of GENERAL MOTORS CORP.
  23. Install J 8001  (3) onto the J 44757-6. See Special Tools . Position the tip (2) of the indicator onto the end of the J 44757-2.
  24. Tighten the nut (4) of the J 44757-2 to preload to the bearings and position the shaft at the bottom of travel. Use a second wrench to hold the J 44757-2 shaft. Observe the needle on the dial. When the needle movement stops, the shaft is at bottom of travel.
  25. Zero the dial indicator.
  26. Loosen and back-off the nut (4).
  27. Tighten the nut (1) to preload the bearings and position the shaft at the top of travel. Use a second wrench to hold the J 44757-2 shaft.
  28. Record the measured value on the dial indicator. Subtract the measured value from 6.0 mm (0.236 in) in order to determine the driveshaft shim required for proper bearing installation and preload.
    29. Fig 21: View Of Shaft, J 44757-7 Shim & Bearing
    GM1486696Courtesy of GENERAL MOTORS CORP.
  29. Disassemble the shaft (1), bearing (3) and J 44757-7 shim (2) from the left case.
  30. Install the proper size shim (2), shaft (1), bearing (3).
    31. Fig 22: Installing Driveshaft Bearing & Shim With J 5590
    GM659155Courtesy of GENERAL MOTORS CORP.
  31. Lightly lubricate the splines of the driveshaft with grease.
  32. Use the J 5590  (1) and a hydraulic press in order to install the bearing, proper size shim and gear (2) onto the shaft.
    33. Fig 23: Identifying Left Case & J 44755
    GM746840Courtesy of GENERAL MOTORS CORP.
  33. Install the left case (2) onto the J 44755  (1). See Special Tools . Align the notched area of the tool with the flat areas of the driveshaft.
    34. Fig 24: Locating Driveshaft Nut
    GM630593Courtesy of GENERAL MOTORS CORP.
  34. Install a new nut (1) onto the driveshaft.

    Tighten:  Tighten the nut to 505 N.m (372 lb ft).

  35. Measure the rotating torque of the driveshaft. A properly assembled shaft and bearings should have a rotating torque of 1.5 N.m (13 lb in).
    36. Fig 25: View Of Carrier Bearing Inner Race & J 44752
    GM746895Courtesy of GENERAL MOTORS CORP.
  36. Use the J 44752  (1) and a hydraulic press in order to install the carrier bearing inner race to the right case. See Special Tools .
    37. Fig 26: Installing Carrier Bearing Outer Race Using J 44752
    GM746896Courtesy of GENERAL MOTORS CORP.
  37. Use the J 44752  (1) and a hydraulic press in order to install the carrier bearing outer race to the right case. See Special Tools .
    38. Fig 27: Using J 44752 To Install Inner Bearing
    GM746897Courtesy of GENERAL MOTORS CORP.
  38. Use the J 44752  (1) and a hydraulic press in order to install the inner bearing to the differential carrier. See Special Tools .
    39. Fig 28: View Of Differential Carrier, Bearing, Shim & Right Case
    GM1486583Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The J 44757-4 shim is installed to create measurable end play and assist in determining the proper size shim for bearing preload.
  39. Install the carrier (4), J 44757-4 shim (3) and bearing (1) to the right case (2).
    40. Fig 29: Installing Carrier, J 44757-4 Shim and Bearing To The Right Case
    GM659133Courtesy of GENERAL MOTORS CORP.
  40. Use the J 44752  (1) and a hydraulic press in order to install the carrier, J 44757-4 shim and bearing to the right case. See Special Tools .
    41. Fig 30: Identifying Right Case & J 44755
    GM746847Courtesy of GENERAL MOTORS CORP.
  41. Install the right case (1) onto the J 44755  (2). See Special Tools . Position the carrier onto the post of the fixture.
    42. Fig 31: Installing J 44757-5 Onto The Carrier
    GM746892Courtesy of GENERAL MOTORS CORP.
  42. Install the J 44757-5 (5) onto the carrier. Tighten until snug.
  43. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), nuts and washers (3) and nuts (6) to the right case.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  44. Rotate the differential carrier multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
    45. Fig 32: Using J 8001 & J 44757 Components To Determine Shim Size
    GM746894Courtesy of GENERAL MOTORS CORP.
  45. Install J 8001  (3) onto the J 44757-6. See Special Tools . Position the tip (2) of the indicator onto the end of the J 44757-5.
  46. Tighten the nut (4) of the J 44757-5 to preload to the bearings and position the differential carrier at the bottom of travel. Use a second wrench to hold the J 44757-5 shaft. Observe the needle on the dial. When the needle movement stops, the carrier is at bottom of travel.
  47. Zero the dial indicator.
  48. Loosen and back-off the nut (4).
  49. Tighten the nut (1) to preload the bearings and position the carrier at the top of travel. Use a second wrench to hold the J 44757-5 shaft.
  50. Record the measured value on the dial indicator. Subtract the measured value from 10 mm (0.394 in) in order to determine the carrier shim required for proper bearing installation and preload.
    51. Fig 33: View Of Differential Carrier, Bearing, Shim & Right Case
    GM1486583Courtesy of GENERAL MOTORS CORP.
  51. Disassemble the carrier (4), bearing (1) and J 44757-4 shim (3) from the right case (2).
  52. Install the proper size shim (3), carrier (4) and bearing (1) to the right case (2).
    53. Fig 34: Installing Carrier, J 44757-4 Shim & Bearing To Right Case
    GM659133Courtesy of GENERAL MOTORS CORP.
  53. Use the J 44752  (1) and a hydraulic press in order to install the shaft, proper size shim and bearing to the right case. See Special Tools .
    54. Fig 35: Locating Differential Carrier Nut
    GM630597Courtesy of GENERAL MOTORS CORP.
  54. Install the nut (1) to the differential carrier.

    Tighten:  Tighten the nut to 500 N.m (369 lb ft).

  55. Measure the rotating torque of the carrier. A properly assembled carrier and bearings should have a rotating torque of 1.5 N.m (13 lb in).
  56. Using a punch, stake the flange of the nut to the groove in the carrier shaft.
    57. Fig 36: Installing Seal To Right Case Using J 44752
    GM747660Courtesy of GENERAL MOTORS CORP.
  57. Use the J 44752  (1) in order to install the seal (2) to the right case. See Special Tools .
    58. Fig 37: Identifying Right Case & J 44755
    GM746847Courtesy of GENERAL MOTORS CORP.
  58. Remove the right case (1) and carrier from the J 44755  (2). See Special Tools .
    59. Fig 38: Installing Housing & Shim To Left Case
    GM754869Courtesy of GENERAL MOTORS CORP.
  59. Install a random size shim (3), housing (2) and bolts (1 and 4) to the left case.

    Tighten: 

    • Tighten the M8 bolts to 32 N.m (23 lb ft).
    • Tighten the M10 bolts to 60 N.m (44 lb ft).

    60. Fig 39: Identifying Extension Housing Assembly, Shim & Bolts
    GM630584Courtesy of GENERAL MOTORS CORP.
  60. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the shim (2).
  61. Install the housing (1), selected shim (2) and bolts (3) to the housing.

    Tighten:  Tighten the bolts to 32 N.m (23 lb ft).

    62. Fig 40: Aligning J 8001 Against Flat Area Of Bolt
    GM659148Courtesy of GENERAL MOTORS CORP.
  62. Install an M8 x 1.25 bolt (1) into a threaded hole in the flange.
  63. Position the top of J 8001  (2) against the flat area of the bolt. See Special Tools .
    64. Fig 41: Locating Driveshaft Nut
    GM754871Courtesy of GENERAL MOTORS CORP.
  64. Install a wrench or socket onto the nut (1) of the driveshaft. Do not allow the shaft to rotate or move when measuring backlash.
  65. Rotate the flange (2) left and right in order to measure the drive and drivenshafts gear backlash. Measure the backlash in multiple locations. The correct gear backlash is 0.2-0.3 mm (0.0078-0.0118 in).
    66. Fig 42: Locating Adjustment Shim
    GM659147Courtesy of GENERAL MOTORS CORP.
  66. Select and install the correct shim (4) to obtain the proper backlash. A change in shim thickness has a one-to-one ratio and change in gear backlash.
    • A thicker shim will increase backlash.
    • A thinner shim will decrease backlash.
  67. Install a new O-ring (5) during final assembly.
    68. Fig 43: View Of Idler Gear
    GM630596Courtesy of GENERAL MOTORS CORP.
  68. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the sealing surfaces of the right case.
  69. Install the idler gear (1) to the right case.
    70. Fig 44: Identifying Idler Gear Long Flange Area
    GM659130Courtesy of GENERAL MOTORS CORP.
  70. Install the idler gear into the right case. The side of the gear with the long flange area (1) should be installed to the right case.
    71. Fig 45: View Of J 44755 Installed To Left Case
    GM630592Courtesy of GENERAL MOTORS CORP.
  71. Rotate the J 44755  90 degrees. See Special Tools .
  72. Install the right case (2) to the left case (1).
    73. Fig 46: Illustrating Case Bolt Tightening Sequence
    GM1486711Courtesy of GENERAL MOTORS CORP.
  73. Install the bolts (1) and tighten as follows:

    Tighten:  Tighten the M8x40 case bolt (1) to 32 N.m (24 lb ft).

    Tighten:  Tighten the M10x60 case bolts (2) to 60 N.m (44 lb ft)

    Tighten:  Tighten the M10x50 case bolt (3) LY7 only to 60 N.m (44 lb ft)

    Tighten:  Tighten the M10x75 case stud bolts (4) LY7 only to 60 N.m (44 lb ft)

    74. Fig 47: Locating Speed Sensor
    GM630579Courtesy of GENERAL MOTORS CORP.
  74. Install the speed sensor (1) and O-ring.
    75. Fig 48: View Of Transfer Case Hose/Clamp Assembly, Vent Hose, Bracket & Bolt
    GM630581Courtesy of GENERAL MOTORS CORP.
  75. Install the hose and clamp (1), vent hose (2) and bolt (3).

    Tighten:  Tighten the vent hose/speed sensor bolt to 30 N.m (22 lb ft).

    76. Fig 49: Identifying Drain Plug
    GM630590Courtesy of GENERAL MOTORS CORP.
  76. Install the transmission oil drain plug (1) and gasket.

    Tighten:  Tighten the drain plug to 32 N.m (24 lb ft).

    77. Fig 50: View Of Fill & Drain Plugs
    GM630583Courtesy of GENERAL MOTORS CORP.
  77. Install the gear oil drain plug (1) and gasket.

    Tighten:  Tighten the drain plug to 32 N.m (24 lb ft).

    78. IMPORTANT: The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer located behind the transmission sun gear. The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components, excluding gaskets and seals, are replaced.
  78. Perform the transfer case selective washer measurement procedure as required. Refer to Transmission to Transfer Case End Play Check (F4WD Only) in Transmission Unit Repair 4T65-E.

    Refer to the Installation and Fluid Fill Procedure in Transfer Case and/or Seal Replacement  in Transfer Case - Steyr Service Information.

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