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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1767 (Transfer Case - NVG 900) >> Repair Instructions >> Differential Carrier Seal Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Installing Inner Oil Seal Using J44871 & Driver Handle
    GM934736Courtesy of GENERAL MOTORS CORP.
    NOTE: The bearing cup must be removed in order to install the seal. If the bearing cup is not removed first, seal damage may occur.
    IMPORTANT: Clean the seal bores before installing the new seals. Inspect the bores for nicks caused by seal removal.
  1. Using J 44871  and a driver handle, install the inner oil seal into the cover. See Special Tools .
    2. Fig 2: Shim & Bearing Cup
    GM934763Courtesy of GENERAL MOTORS CORP.
  2. Install the shim (2) and the bearing cup (3) into the side cover (1).
    3. Fig 3: Installing Cup & Shim Using J44875
    GM934771Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not heat the cover to install the cup. Heating the cover will damage the seal.
  3. Using J 44875  and a driver handle, install the cup and the shim. See Special Tools .
    4. Fig 4: Removing Bearing Cup Or Shims In Order To Remove Seal From Carrier Assembly
    GM696454Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: It is not necessary to remove the bearing cup or shims in order to remove the seal from the carrier assembly housing.
  4. Drive the seal (1) out from the inside of the carrier assembly housing.
    5. Fig 5: Installing Oil Seal On Housing Using J44871
    GM934708Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not install the seal from inside of the housing. The outside diameter of the bearing cup may cause seal damage.
    IMPORTANT: Clean the seal bores before installing new seals. Inspect the bores for nicks caused by seal removal.
  5. Using J 44871  and a driver handle, install the oil seal to the housing. See Special Tools .
    6. Fig 6: Cleaning Carrier Assembly Housing Sealing Surface
    GM850510Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use motor-powered tools to clean surfaces.
  6. Clean the carrier assembly housing sealing surface (1) with solvent and scrape it clean with a razor blade.
    7. Fig 7: Cleaning Cover Sealing Surface
    GM850512Courtesy of GENERAL MOTORS CORP.
  7. Clean the cover sealing surface (1) with solvent and scrape it clean with a razor blade.
    8. Fig 8: Installing Carrier Assembly To Housing
    GM850523Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Grease the seal lips in order to protect the seal and to ease in assembly.
  8. Install the carrier assembly (1) to the housing.
    9. Fig 9: Applying Sealer To Housing
    GM934846Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not apply excess sealer. Excess sealer could cause premature failure.
  9. Apply a 2-3 mm (0.8-0.12 in) amount of sealer Saturn P/N 1052943, or equivalent, to the housing (1).
    10. Fig 10: Side Cover & Bolts
    GM934818Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to FASTENER NOTICE in Cautions and Notices.
    IMPORTANT: Grease the seal lips in order to protect the seal and to ease in assembly. Coat bolt threads with sealant Saturn P/N 12345382.
  10. Install the side cover (1) and bolts (2 and 3) to the housing.

    Tighten:  Tighten the side cover bolts to 37 N.m (27 lb ft).

  11. Install the drain plug. Apply sealant Saturn P/N 21485278 to the threads.

    Tighten:  Tighten the drain plug 24 N.m (18 lb ft).

  12. Fill the transfer case with fluid, after it is installed in the vehicle, to the bottom of the fill plug hole, or 540 ml (18.2 oz).
  13. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads.

    Tighten:  Tighten the fill plug 15 N.m (11 lb ft).

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