Transfer Case Reassembly

NOTE: See Figure for exploded view of transfer case. When installing bearings, ensure bearing bores are aligned with oil feed holes.

NOTE: Lubricate all components with Dexron ATF during assembly.

Assemble spring retainers to synchronizer hub, align scribe marks on hub to sleeve and assemble hub with struts. Assemble main drive synchronizer stop ring to sleeve. Install drive sprocket to mainshaft and install synchronizer assembly to mainshaft. Install synchronizer snap ring to mainshaft. With soft-face hammer, install input gear and planetary assembly to annulus gear. Install magnet in case slot.
Install snap ring to input bearing. Apply RTV sealant to bearing retainer mating surfaces (except over bolt holes). Apply thread lock seal and install input shaft bearing retainer bolts and tighten to specifications. See TORQUE SPECIFICATIONS . Install 3 bolts holding encoder motor to front case. Tighten to specifications.
Rotate sector to align range shift fork and install range shift hub into front case half. Install front output shaft to front case half. Install driven sprocket to chain. Install drive chain onto drive sprocket, noting location of master link, as removed. Install mainshaft, driven sprocket and drive chain as an assembly to front case half. Install drive chain onto drive sprocket. Install driven gear snap ring on front output shaft. See Fig 1 .

Fig 1: Installing Output Shaft & Drive Chain Assembly
Courtesy of GENERAL MOTORS CORP.
Install mode shift fork onto shift rail. Install mode shift fork assembly onto synchronizer sleeve, through range shift fork and into front case half. Install mode shift fork spring to shift rail. See Fig 2 .

Fig 2: Identifying Synchronizer & Mode Fork Components
Courtesy of GENERAL MOTORS CORP.
Install oil pump pickup tube, connector and screen to rear case half. See Fig 3 . Install "O" ring into oil pump. Lubricate oil pump pickup tube with ATF and install oil pump to pickup tube. Clean front case half mating surfaces. Apply RTV sealant to surfaces, then install dowels into front case half.

Fig 3: Removing & Installing Oil Pump Oil Screen
Courtesy of GENERAL MOTORS CORP.
Install rear case half over mainshaft and onto front case half. Use care to avoid damaging oil pump. Apply thread lock compound to case bolts. Install bolts, noting proper locations of longer bolts and washers. Tighten to specifications. TORQUE SPECIFICATIONS .
Install snap ring behind speedometer tone wheel on mainshaft, install tone wheel, then install front snap ring. Apply thread lock compound to rear retainer housing bolts. Install housing and tighten bolts to specifications. See TORQUE SPECIFICATIONS .
Install NEW output bearing snap ring to mainshaft. Apply RTV sealant to rear retainer housing-to-extension housing mating surface. Apply thread lock compound to extension housing bolts. Install extension housing and bolts. Tighten to specifications. See TORQUE SPECIFICATIONS .
Install detent pin, detent spring, "O" ring and detent plug. Tighten plug to specifications. See TORQUE SPECIFICATIONS . Install vehicle speed sensor and "O" ring to rear retainer housing. Tighten to specifications. Install 4WD actuator switch and "O" ring to front case half. Tighten to specifications. See TORQUE SPECIFICATIONS . Install front output yoke, rubber sealing washer, metal washer and nut. Tighten NEW yoke nut to specifications. SeeTORQUE SPECIFICATIONS .
Install needle bearing to rear case until flush with boss. Install front output bearing and snap ring to front case. Install bearing into rear retainer housing. Install mainshaft pilot bearing into input gear. Install thrust washer into planetary carrier and install snap ring. Install bearing and snap ring into input gear.
Install input bearing retainer seal to input bearing retainer. Install oil seal to rear extension housing. Install seal to input bearing retainer. Install front output shaft seal to front case half. Install front case magnet.