Transfer Case Assemble

Tools Required

• J 5590  Pinion Bearing Race Installer - Rear
• J 8092  Driver Handle
• J 24433  Pinion Cone and Side Bearing Installer. See Special Tools .
• J 36850  Transjel Lubricant
• J 46268  Output Seal Installer. See Special Tools .
• J 46269  Input Seal Installer. See Special Tools .

Fig 1: Installing Input Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Lubricate all bearings and bearing journals with transfer case fluid during installation.
• Use a hammer and a brass drift only on the outer bearing race.
• Ensure the bearing is kept square to the bore while installing.
1. Install the input shaft bearing (117) into the case (1).
Fig 2: Installing Front Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Use a hammer and a brass drift only on the outer bearing race.
• Ensure the bearing is kept square to the bore while installing.
2. Install the front output shaft bearing (113) into the case (1).
Fig 3: Installing Input Shaft Oil Seal Using J 46269 & J 8092
Courtesy of GENERAL MOTORS CORP.
3. Using the J 46269  (2) and the J 8092  (1), install the input shaft oil seal (13).
Fig 4: Installing Front Output Shaft Oil Seal Using J 46268 & J 8092
Courtesy of GENERAL MOTORS CORP.
4. Using the J 46268  (2) and the J 8092  (1), install the front output shaft oil seal (14).
Fig 5: Identifying Chain Snubber & Bolts
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice in Cautions and Notices.
5. Install the chain snubber (3).
6. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bolts (4).

   Tighten:  Tighten the bolts to 7 N.m (62 lb in).

Fig 6: View Of Vent Baffle & Bolt
Courtesy of GENERAL MOTORS CORP.
7. Install the vent baffle (10).
8. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the bolt (9).

   Tighten:  Tighten the bolt to 7 N.m (62 lb in).

Fig 7: View Of Pinion Gear Alignment Marks
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The planetary differential gears are timed to the sun gears. If the gears are not timed properly, the differential will not rotate without binding - 40/60 ratio.
9. With the thrust washer side of the planetary differential facing down, align the marks on the pinion gears. Position the alignment marks with an area on the planetary differential that can be reference for all gears.
Fig 8: View Of Input Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The input shaft (118) must be installed to the carrier (111) with the raised bosses (1) facing up and the thrust washer groove facing down. Reversing this will cause the wrong torque split of 60/40, in some models.
10. Use a press to install the input shaft assembly to the carrier (111).
Fig 9: Installing Thrust Washer & Sun Gear
Courtesy of GENERAL MOTORS CORP.
11. Lubricate the thrust washer (100) with J 36850  or equivalent.
12. Install the thrust washer over the rear of the input shaft, into the groove of the carrier (111).
13. Insert the sun gear (101) into the carrier.
Fig 10: Checking Sun Gear Carrier Assembly Rotation
Courtesy of GENERAL MOTORS CORP.
14. If the pinion gears are properly aligned, the sun gear (101) carrier assembly will rotate freely.
15. Remove the sun gear (101) from the carrier (111).
Fig 11: View Of Snap Ring, Front Output Shaft & Case
Courtesy of GENERAL MOTORS CORP.
16. Assemble the front output shaft (112) to the case (1).
17. Assemble the snap ring (114).
Fig 12: Aligning Chain, Upper Gear & Lower Sprocket To Case
Courtesy of GENERAL MOTORS CORP.
18. Assemble the chain (109), upper gear of the planetary assembly, and lower sprocket (115) to the case (1).
Fig 13: Seating Lower Sprocket To Front Output Shaft
Courtesy of GENERAL MOTORS CORP.
19. Use the J 5590  and a press to fully seat the lower sprocket (115) to the front output shaft, while guiding the input shaft of the planetary assembly, until it is seated to the case.
Fig 14: Installing Rear Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Use a hammer and a brass drift only on the outer bearing race.
• Ensure the bearing is kept square to the bore while installing.
20. Install the rear output shaft bearing (104).
Fig 15: Installing Rear Output Oil Seal Using J 46268 & J 8092
Courtesy of GENERAL MOTORS CORP.
21. Using the J 46268  (2) and the J 8092  (1), install the rear output oil seal (7).
Fig 16: Installing Inner Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Use a hammer and a brass drift only on the outer bearing race.
• Ensure the bearing is kept square to the bore while installing.
22. Install the inner output shaft bearing (103).
Fig 17: Installing Front Output Shaft Inner Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Use a hammer and a brass drift only on the outer bearing race.
• Ensure the bearing is kept square to the bore while installing.
23. Install the front output shaft inner bearing (116).
Fig 18: View Of Snap Ring, Output Shaft & Cover
Courtesy of GENERAL MOTORS CORP.
24. Install the rear output shaft (106) by pushing it in through the bearings.
25. Install the rear output shaft snap ring (102) in the lower groove of the output shaft (106).
Fig 19: Pressing Sun Gear Onto Output Shaft With J 24433
Courtesy of GENERAL MOTORS CORP.
26. Use the J 24433  and a press to install the sun gear (101) to the output shaft. See Special Tools .
Fig 20: Installing Dowel Pins Into Cover
Courtesy of GENERAL MOTORS CORP.
IMPORTANT:
• Ensure both the sealing surfaces on the case and cover are free of dirt, oil and cleaning solvent.
• Ensure the dowel pins (5) are installed in the cover (2).
27. Install the dowel pins (5) into the cover (2), if necessary.
28. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the cover (2).
Fig 21: View Of Case, Cover & Alignment Dowel
Courtesy of GENERAL MOTORS CORP.
29. Insert the dowel pin (3), if removed.
30. Lower the cover (2) over the case (1). Turn the rear output shaft in order to align the splines and the shaft into the bearing in the cover.
Fig 22: Identifying Case Bolts
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The bolts are self-tapping. They must be hand started. Do NOT use power-assisted tools to install the bolts (11).
31. Install the case bolts (11).

    Tighten:  Tighten the case bolts to 25 N.m (18 lb ft) in a criss-cross pattern.

Fig 23: Aligning Vent Breather
Courtesy of GENERAL MOTORS CORP.
32. Install the vent breather by pushing it into the hole. Align the flat on vent with the flat on the case.
33. Lightly pull on the vent to ensure proper installation.
Fig 24: View Of Drain Plug
Courtesy of GENERAL MOTORS CORP.
34. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the drain plug (8).
35. Install the drain plug (8).

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

Fig 25: View Of Fill Plug
Courtesy of GENERAL MOTORS CORP.
36. Fill the transfer case with 1.4 liter (1.5 qt) of DEXRON III® GM P/N 12346143 (Canadian P/N 10952622), or fill to the bottom of fill plug threads. Ensure the vehicle is on a level surface.
37. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the fill plug.
38. Install the fill plug (6).

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

Fig 26: View Of Dampener
Courtesy of GENERAL MOTORS CORP.
39. Install the dampener (300) and the bolts (16).

    Tighten:  Tighten the bolts to 27 N.m (20 lb ft).