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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 >> Pinion Oil 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 Collapsible Spacer, Pinion Shaft & Bearing To Housing
    GM934679Courtesy of GENERAL MOTORS CORP.
  1. Install the NEW collapsible spacer (2) onto the pinion shaft (3).
  2. Install the pinion shaft (3) into the housing.
  3. Install the bearing (1) onto the pinion shaft.
    4. Fig 2: Slinger Washer & Pinion Seal
    GM934672Courtesy of GENERAL MOTORS CORP.
  4. Install the slinger washer (2) and the NEW pinion seal (1) to the housing.
    5. Fig 3: Installing Pinion Seal Using J44872
    GM934832Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Clean the seal bores. Inspect for nicks caused by seal removal.
  5. Using the J 44872  , install the NEW pinion seal. See Special Tools .
    6. Fig 4: Installing Pinion Flange Using Pinion Nut
    GM934598Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use a NEW pinion nut.
  6. Using a NEW pinion nut (1), install the pinion flange (2) to the pinion shaft.
    7. Fig 5: Installing J44873 & 2 Bolts In Order To Hold Pinion Flange
    GM934687Courtesy of GENERAL MOTORS CORP.
  7. Install J 44873  and the 2 bolts supplied in order to hold the pinion flange while tightening the nut.
  8. Tighten the pinion flange nut until it is snug.
    9. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  9. Tighten the nut slowly in order to crush the collapsible spacer.

    Tighten:  Tighten the pinion flange nut to achieve a rotating torque of 0.9-1.6 N.m (8-14 lb in).

    10. Fig 6: Cleaning Carrier Assembly Housing Sealing Surface
    GM850510Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use motor-powered tools to clean surfaces.
  10. Clean the carrier assembly housing sealing surface (1) with solvent and scrape it clean with a razor blade.
    11. Fig 7: Cleaning Cover Sealing Surface
    GM850512Courtesy of GENERAL MOTORS CORP.
  11. Clean the cover sealing surface (1) with solvent and scrape it clean with a razor blade.
    12. Fig 8: Installing Carrier Assembly To Housing
    GM850523Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use gear lubricant fluid Saturn P/N 12378514 to grease the seal lips in order to protect the seal and to ease in assembly.
  12. Install the carrier assembly (1) to the housing.
    13. Fig 9: Applying Sealer To Housing
    GM934846Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not apply excess sealer. Excess sealer could cause premature failure.
  13. Apply a 2-3 mm (0.08-0.12 in) amount of sealer Saturn P/N 1052943 or equivalent to the housing (1).
    14. Fig 10: Side Cover & Bolts
    GM934818Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Grease the seal lips in order to protect the seal and to ease in assembly. Coat the bolt threads with sealant Saturn P/N 12345382.
  14. Install the side cover (1) and bolts (2 and 3) to the housing.

    There is not a specific tightening sequence, but the bolts with dowel pins should be tightened first, and alternate the others from side to side.

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

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

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

  16. 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).
  17. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads.

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

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