Transfer Case Assemble

Special Tools

• J 3289-20  Holding Fixture
• J 8092  Universal Driver
• J 22912-B  Rear Pinion and Axle Bearing Remover
• J 36850  Transjel Lubricant
• J 42176  Universal Driver Handle - Non-Threaded
• J 42738  Seal Installer
• J 43484  Front Output Shaft Seal Installer
• J 45380  Transfer Case Rear Bushing Remover and Installer
• J 45756  Rear Output Shaft Seal Installer
• J 45757  Mainshaft Support Bushing and Bearing Installer
• J 45759  Assembly Fixture

For equivalent regional tools, refer to Special Tools 

Fig 1: Transfer Case Mounting Stud
Courtesy of GENERAL MOTORS CORP.
CAUTION:

Refer to Fastener Caution .

1. If removed, install the transfer case mounting studs. Tighten the mounting studs to 10 N.m (89 lb in).
Fig 2: Front Transfer Case Bench Mount
Courtesy of GENERAL MOTORS CORP.
2. Attach the J 45759  assembly fixture to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759  assembly fixture.
3. Install the J 45759  assembly fixture (2) into the J 3289-20  holding fixture (1) and secure with the pivot pin.
Fig 3: Front Case Vent
Courtesy of GENERAL MOTORS CORP.
4. If the vent is removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
5. Install the vent.
6. Tighten the vent to 6 N.m (53 lb in).
Fig 4: Input Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
NOTE:

Lubricate all of the bearings and bearing journals with transfer case fluid during installation.

7. Install the input shaft bearing 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.
Fig 5: Installing Front Output Shaft Front Bearing
Courtesy 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.
Fig 6: Front Output Shaft Cup Plug
Courtesy of GENERAL MOTORS CORP.
9. 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.
Fig 7: Front Output Shaft Assembly
Courtesy of GENERAL MOTORS CORP.
10. Install the front output shaft assembly.
Fig 8: Input Shaft
Courtesy of GENERAL MOTORS CORP.
11. Install the input shaft.
Fig 9: Drive Chain And Sprockets
Courtesy of GENERAL MOTORS CORP.
NOTE:

If using the chain and sprockets again, ensure to align the marks of the drive chain and sprockets.

12. Install the drive chain and sprockets. The blue link on the chain faces up.
Fig 10: Front Sun Gear
Courtesy of GENERAL MOTORS CORP.
13. Install the front sun gear.
Fig 11: Aligning Marks On Pinion Gears
Courtesy of GENERAL MOTORS CORP.
NOTE:

The planetary differential gears are timed to the sun gears. If the gears are not timed properly, the differential will not rotate without binding.

14. With the rear side of the planetary differential facing up, align the marks on the pinion gears. Position the alignment marks with an area on the planetary housing that can be reference for all gears.
Fig 12: Planetary Differential Assembly
Courtesy of GENERAL MOTORS CORP.
15. Install the planetary differential assembly.
    • Do not rotate the planetary differential pinion gears when installing.
    • Ensure the alignment marks are still in position.
Fig 13: Sun Gear Thrust Washer
Courtesy of GENERAL MOTORS CORP.
16. Lubricate the sun gear thrust washer with J 36850  lubricant, or equivalent.
17. Install the sun gear thrust washer.
Fig 14: Rear Sun Gear
Courtesy of GENERAL MOTORS CORP.
18. Install the rear sun gear.
    • The shoulder side of the gear faces up.
    • Do not rotate the planetary pinion gears.
Fig 15: Checking Planetary Differential Pinion Gear Rotation
Courtesy of GENERAL MOTORS CORP.
19. Temporarily install the rear output shaft to the planetary differential and the rear sun gear.
20. Rotate the rear output shaft three or four revolutions to rotate the planetary differential pinion gears. If properly aligned, the planetary pinion gears will rotate freely, and there will be no binding.
21. Remove the rear output shaft without disturbing the rear sun gear.
Fig 16: Front Output Shaft Rear Bearing
Courtesy of GENERAL MOTORS CORP.
22. 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.
Fig 17: Installing Rear Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
23. Using a hydraulic press and the J 22912-B  bearing remover, install the rear output shaft bearing.
    • The retaining ring groove on the bearing goes toward the input end or forward.
    • Use a suitable press plate on the end of the rear output shaft.
    • Ensure the bearing is supported on the inner race.
Fig 18: Rear Output Shaft Bearing Retaining Ring
Courtesy of GENERAL MOTORS CORP.
24. Install a NEW retaining ring for the rear output shaft bearing.
Fig 19: Input Shaft Rear Support Bushing And Special Tools
Courtesy of GENERAL MOTORS CORP.
25. Using the J 42176  driver handle (1) and the J 45757  bushing and bearing installer (2), install the input shaft rear support bushing in the rear output shaft.
Fig 20: Rear Output Shaft And Rear Case Half
Courtesy of GENERAL MOTORS CORP.
26. Install the rear output shaft in the rear case half.
    1. Spread the rear output shaft rear bearing outer retaining ring.
    2. Install, until the rear output shaft bearing outer retaining ring is seated in the bearing groove.
Fig 21: Mating Surfaces On Case Half
Courtesy of GENERAL MOTORS CORP.
NOTE:
• Ensure 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 case halves.
27. Install the locating pins in the front case and rear case half, if necessary.
28. 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.
Fig 22: Rear Case Half And Front Case Half
Courtesy of GENERAL MOTORS CORP.
29. Lower the rear case half into place.

    The rear output may require rotating to align the teeth with the planetary carrier.

Fig 23: Transfer Case Retaining Bolts And Washers
Courtesy of GENERAL MOTORS CORP.
CAUTION:

This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. New nylon coated case bolts and aluminum washers must be used. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.

30. Inspect the nylon coating on the case bolts for cuts or tears.
31. Replace the case bolts if there is any damage to the nylon coating.
NOTE:

The case bolts are self-tapping; they must be hand started. Do not use power assisted tools to install the bolts.

32. Install the case bolts, the washers, and the brackets.
33. Tighten the case bolts to 21 N.m (15 lb ft).
Fig 24: Installing Output Shaft Bushing
Courtesy of GENERAL MOTORS CORP.
NOTE:

Install the bushing with the notched area facing outward and properly aligned to the rear case.

34. Using J 45380  bushing remover and installer, install the output shaft bushing, if removed or new.
Fig 25: Rear Output Shaft Seal And Special Tool
Courtesy of GENERAL MOTORS CORP.
35. Using J 45756  seal installer, install the rear output shaft seal.
Fig 26: Transfer Case Drain Plug
Courtesy of GENERAL MOTORS CORP.
36. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
37. Install the drain plug and the fill plug.
38. Tighten the drain plug and fill plug to 25 N.m (18 lb ft).
Fig 27: Installing Transfer Case Output Seal
Courtesy of GENERAL MOTORS CORP.
39. Using the J 43484  seal installer (2) and the J 8092  driver (1), install the front output shaft seal.
Fig 28: Installing Input Shaft Seal
Courtesy of GENERAL MOTORS CORP.
40. Using the J 42738  seal installer, install the front input shaft seal.
41. Remove the transfer case from the J 45759  assembly fixture.