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Transaxle-To-Transfer Case End Play

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NOTE: Tools required: Assembly Lubricant (or equivalent) (J-36850) and End Play Checking Tool (J-44472).
NOTE: Transaxle oil circulates between the transaxle assembly and the transfer case. In situations where transaxle related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned and inspected for damage.
  1. Position the transaxle so that the case side cover is facing down.
  2. Install the final drive sun gear shaft. See Fig 1.
    CAUTION: The park gear thrust bearing must be retained in the park gear when installing the transfer case to the transaxle, or damage may occur.
  3. Use assembly lubricant or equivalent in order to retain the parking gear thrust bearing to the parking gear. Install the parking gear thrust bearing and the parking gear. See Fig 2.
    NOTE: The counterbore on the final drive sun gear installs towards the parking gear.
  4. Install the final drive sun gear. See Fig 3.
  5. Install the gauge bar (1) onto the case mounting surface. See Fig 4.
    Fig 1: Removing & Installing Final Drive Sun Gear Shaft
    G00057598Courtesy of GENERAL MOTORS CORP.
    Fig 2: Removing & Installing Parking Gear & Bearing
    G00057597Courtesy of GENERAL MOTORS CORP.
    Fig 3: Removing & Installing Final Drive Sun Gear
    G00057595Courtesy of GENERAL MOTORS CORP.
    Fig 4: Checking Transaxle-To-Transfer Case End Play (Dimension "A")
    G00073388Courtesy of GENERAL MOTORS CORP.
    NOTE: Install bolts to end play checking tool and tighten securely to prevent tool deflection during end play measurement.
  6. Install end play checking tool onto the transaxle. Tighten end play checking tool to remove end play. Hand tighten only.
  7. Measure the distance from the case mounting surface, bottom of the gauge bar (1) to the top of the final drive sun gear. See Fig 4. This measurement is dimension "A". See Fig 5.
  8. Remove the gauge bar (1) and end play checking tool.
  9. Install the gauge bar onto the carrier.
  10. Measure the distance from the bottom of the gauge bar to the transfer case. See Fig 6. This measurement is dimension "B1".
  11. Measure the distance from the bottom of the gauge bar to the thrust bearing (1). See Fig 7. This measurement is dimension "B2".
    Fig 5: Transfer Case Selective Washer Specifications
    G00073390Courtesy of GENERAL MOTORS CORP.
    Fig 6: Checking Transaxle-To-Transfer Case End Play (Dimension "B1")
    G00073386Courtesy of GENERAL MOTORS CORP.
    Fig 7: Checking Transaxle-To-Transfer Case End Play (Dimension "B2")
    G00073387Courtesy of GENERAL MOTORS CORP.
  12. Subtract dimension "B2" from dimension "B1". This dimension is "B". See Fig 5.
  13. Remove the gauge bar from the transfer case.
  14. Remove the final drive sun gear. See Fig 3.
  15. Install the selective washer. See Fig 8.
    Fig 8: Removing & Installing Sun Gear Thrust Washer
    G00057596Courtesy of GENERAL MOTORS CORP.
    NOTE: The counterbore on the final drive sun gear installs towards the parking gear.
  16. Install the final drive sun gear. See Fig 3.
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