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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 22 (Transfer Case - BW 4473-NP3) >> Repair Instructions - Off Vehicle >> Transfer Case Assemble

Transfer Case Assemble

WARNING: This page is about a different variant/trim than selected.

Tools Required

    Fig 1: Identifying Transfer Case Mounting Studs
    GM823238Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  1. If removed, install the transfer case mounting studs.

    Tighten:  Tighten the mounting studs to 10 N.m (89 lb in).

    2. Fig 2: View Of J 45759 & J 3289-20
    GM823195Courtesy of GENERAL MOTORS CORP.
  2. Attach the J 45759  (2) to the front case half using the adapter studs. See Special Tools . All of the assembly procedures can be performed with the case mounted to the J 45759  (2). See Special Tools .
  3. Install the J 45759  (2) into the J 3289-20  (1) and secure with pivot pin. See Special Tools .
    4. Fig 3: View Of Transfer Case Vent
    GM823229Courtesy of GENERAL MOTORS CORP.
  4. If removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
  5. Install the vent.

    Tighten:  Tighten the vent to 6 N.m (53 lb in).

    6. Fig 4: View Of Front Output Shaft Rear Bearing
    GM819637Courtesy of GENERAL MOTORS CORP.
  6. Install the front output shaft rear bearing in the rear case half.
    • Use a hammer and a brass drift only on the outer bearing race.
    • Ensure the bearing is kept square to the bore while installing.
    7. Fig 5: View Of Input Shaft Bushing In The Front Case Half
    GM823239Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate all bearings and bearing journals with transfer case fluid during installation.
  7. Install the input shaft bushing in the front case half using the J 36373  and a hammer. See Special Tools .
    8. Fig 6: Aligning Brass Drift On Outer Bearing Race
    GM819641Courtesy of GENERAL MOTORS CORP.
  8. Install the front bearing for the front output shaft in the front case half.
    • Use a hammer and a brass drift only on the outer bearing race.
    • Ensure the bearing is kept square to the bore while installing.
    9. Fig 7: Identifying Input Shaft Rear Support Bearing In The Rear Output Shaft
    GM823240Courtesy of GENERAL MOTORS CORP.
  9. If removed, install the input shaft rear support bearing in the rear output shaft using J 42176  (1) and J 45848  (2). See Special Tools .
    10. Fig 8: View Of J 22828 Installing Rear Output Shaft Bearing
    GM823241Courtesy of GENERAL MOTORS CORP.
  10. Using the J 22828  and a hydraulic press, install the rear output shaft bearing with the retaining ring groove towards the gear. See Special Tools .
    11. Fig 9: View Of Speed Reluctor Wheel & J 22828
    GM823242Courtesy of GENERAL MOTORS CORP.
  11. Using the J 22828  and a hydraulic press, install a NEW speed reluctor wheel. See Special Tools .
    12. Fig 10: Identifying Rear Output Shaft Bearing Retaining Ring
    GM823236Courtesy of GENERAL MOTORS CORP.
  12. Install a NEW retaining ring for the rear output shaft bearing.
    13. Fig 11: View Of Rear Output Shaft From The Annulus Gear
    GM823232Courtesy of GENERAL MOTORS CORP.
  13. Install the rear output shaft in the annulus gear.
    14. Fig 12: Locating Annulus Gear Retaining Ring
    GM823231Courtesy of GENERAL MOTORS CORP.
    CAUTION: The vehicle could roll while in park if the annulus gear becomes disengaged from the rear output shaft. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.
    NOTE: Damage may occur to the viscous coupling if the retaining ring for the rear output shaft to the annulus gear fails or becomes dislodged during vehicle operation. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.
  14. Install a NEW annulus gear retaining ring.
    15. Fig 13: Spreading Rear Output Shaft Rear Bearing Outer Retaining Ring
    GM1266756Courtesy of GENERAL MOTORS CORP.
  15. Install the rear output shaft in the rear case.
    • Spread the rear output shaft rear bearing outer retaining ring (1).
    • Using a soft-face hammer, tap on the rear output shaft.
  16. Ensure the retaining ring (1) is installed in the groove of the rear output shaft bearing (2).
    17. Fig 14: Locating Input Shaft
    GM823222Courtesy of GENERAL MOTORS CORP.
  17. Install the input shaft in the front case.
    18. Fig 15: Identifying Viscous Coupling
    GM823221Courtesy of GENERAL MOTORS CORP.
  18. Install the viscous coupling on the sun gear.
    19. Fig 16: View Of Drive Gear From Sun Gear Assembly
    GM823220Courtesy of GENERAL MOTORS CORP.
  19. Install the drive gear on the sun gear.
    20. Fig 17: Using J 45540 & J 5590 To Install Sun Gear Bearing
    GM823243Courtesy of GENERAL MOTORS CORP.
  20. Using a hammer with the J 45540  (2) and the J 5590  (1), install the bearing on the sun gear. Ensure the bearing is fully seated against the drive gear. See Special Tools .
    21. Fig 18: View Of Sun Gear Assembly
    GM823216Courtesy of GENERAL MOTORS CORP.
  21. Install the sun gear, with the drive gear and the viscous coupling, on the input gear.
    22. Fig 19: View Of Front Output Shaft Cup Plug
    GM819644Courtesy of GENERAL MOTORS CORP.
  22. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver. Install the cup plug 1 mm (0.039 in) from flush with the end of the shaft.
    23. Fig 20: View Of Drive Gear From Sun Gear Assembly
    GM823220Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure to align the marks of the drive chain and sprockets, if using the chain and sprockets again.
  23. Install the drive chain on the drive sprocket.
    • The blue link on the chain faces up.
    • Align the chain, if using it again, with the alignment marks made during disassembly.
    24. Fig 21: View Of Chain With Driven Sprocket
    GM823213Courtesy of GENERAL MOTORS CORP.
  24. Install the driven sprocket and the chain.
    25. Fig 22: View Of Front Input Shaft
    GM823211Courtesy of GENERAL MOTORS CORP.
  25. Install the front output shaft in the driven sprocket and the bearing.
    26. Fig 23: Locating Sun Gear Thrust Washer
    GM823207Courtesy of GENERAL MOTORS CORP.
  26. Lubricate the sun gear thrust washer with J 36850  or equivalent. See Special Tools .
  27. Install the sun gear thrust washer.
    28. Fig 24: Identifying Planetary Carrier Assembly
    GM823206Courtesy of GENERAL MOTORS CORP.
  28. Install the planetary carrier assembly.
    29. Fig 25: View Of Planetary Carrier Assembly Thrust Washer
    GM823196Courtesy of GENERAL MOTORS CORP.
  29. Lubricate the sun gear thrust washer with J 36850  or equivalent. See Special Tools .
  30. Install the planetary carrier thrust washer.
    31. Fig 26: View of Front Case Half
    GM823244Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Ensure that both the sealing surfaces on the front and rear case halves are free of dirt, oil, and cleaning solvent.
    • Ensure the locating pins are installed in the front case half.
  31. Install the locating pins in the front case, if necessary.
  32. Apply a 3.175 mm (1/8 in) bead of room temperature vulcanizing (RTV) sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.
    33. Fig 27: View Of Rear Case Half & Front Case Half
    GM823209Courtesy of GENERAL MOTORS CORP.
  33. Lower the rear case half into place.
    34. Fig 28: Locating Transfer Case Retaining Bolts
    GM823204Courtesy of GENERAL MOTORS CORP.
  34. Install the case bolts, the washers, and the brackets.

    Tighten:  Tighten the case bolts to 21 N.m (15 lb ft).

    35. Fig 29: Installing Rear Output Shaft Seal Using Screwdriver
    GM819663Courtesy of GENERAL MOTORS CORP.
  35. Using the J 45756  , install the rear output shaft seal. See Special Tools .
    36. Fig 30: View Of Vehicle Speed Sensor (VSS) With O-Ring Seal
    GM823198Courtesy of GENERAL MOTORS CORP.
  36. Install the vehicle speed sensor with a NEW O-ring seal.

    Tighten:  Tighten the speed sensor to 17 N.m (13 lb ft).

    37. Fig 31: View Of Transfer Case Drain Plug
    GM823193Courtesy of GENERAL MOTORS CORP.
  37. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
  38. Install the drain plug and the fill plug.

    Tighten:  Tighten the drain plug and fill plug to 25 N.m (18 lb ft).

    39. Fig 32: Installing J 43484 To J 8092
    GM819655Courtesy of GENERAL MOTORS CORP.
  39. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal. See Special Tools .
    40. Fig 33: Installing Front Input Shaft Seal With J 45758
    GM823255Courtesy of GENERAL MOTORS CORP.
  40. Using the J 45758  , install the front input shaft seal. See Special Tools .
  41. Remove the transfer case from the J 45759  . See Special Tools .
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