Assembly Procedure

1. Install the inner shaft bearing, print side out, into the intermediate shaft bearing housing inner case half using the J 45232  (2) and the J 8092  (1).
   Fig 1: Installing Inner Shaft Bearing Using J 45232 (2) And J 8092 (1)

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2. Install the inner shaft bearing, print side out, into the intermediate shaft bearing housing outer case half using the J 45232  (2) and the J 8092  (1).
   Fig 2: Installing Inner Shaft Bearing Using J 45232 (2) And J 8092(1)

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3. Install the inner axle bearing, print side out, into the intermediate shaft bearing housing outer case half using the J 45232  (2) and the J 8092  (1).
   Fig 3: Installing Inner Axle Bearing Using J 45232 (2) And J 8092(1)

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4. Install the thrust washer.
   Fig 4: Installing Thrust Washer

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5. Install the inner clutch fork gear.
   Fig 5: Installing Inner Clutch Fork Gear

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6. Install the clutch fork spring.
   Fig 6: Installing Clutch Fork Spring

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7. Install the washer.
   Fig 7: Installing Washer

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8. Install the clutch fork and clutch fork sleeve.
   Fig 8: Installing Clutch Fork And Clutch Fork Sleeve

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9. Install the outer clutch fork gear.
   Fig 9: Installing Outer Clutch Fork Gear

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10. Install the thrust washer to the outer intermediate shaft bearing housing case half.

    Use grease to hold the thrust washer in place.

11. Apply a bead of sealant, GM P/N 1052942 or equivalent, to the sealing surface of one side of the intermediate shaft bearing housing case.
12. Install the outer intermediate shaft bearing housing case to the inner intermediate shaft bearing housing case.
    Fig 10: Installing Thrust Washer

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    NOTE: Refer to Fastener Notice in Cautions and Notices.
13. Install the intermediate shaft bearing case bolts.

    Tighten 

    Tighten the intermediate shaft bearing case bolts to 48 N.m (35 lb ft).

    Fig 11: Installing Intermediate Shaft Bearing Case Bolts

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14. Install the new inboard, oil pan side, seal on top of the seal bore.
15. Install the new seal using the J 45225  (2) and the J 8092  (1).
    Fig 12: Installing Seal Using J 45225(2) And J 8092(1)

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    NOTE: The outboard intermediate shaft bearing assembly seal must be installed 0.9-1.1 mm (0.035-0.043 in) below the surface of the intermediate shaft bearing assembly housing bore. If the seal is not installed properly, damage to the seal may occur.
16. Install the new seal using the J 45359  (2) and the J 8092  (1).
    Fig 13: Installing New Seal Using J 45359(2) And J 8092(1)

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17. Pack the cavity of the inner intermediate shaft bearing housing with 55-65 cc (1.86-2.20 oz) of grease, GM P/N 12377985 or equivalent.
    Fig 14: Locating Bearing Housing

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18. Install the actuator.
19. Install the actuator bolts.

Tighten 

Tighten the actuator bolts to 6 N.m (53 lb in).

Fig 15: Installing Actuator Bolts

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