Transfer Case Assemble

WARNING: This page is about a different car, the 2001 Oldsmobile Bravada, 2001 GMC Safari, and 2001 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 37668-A JD 37668-A Seal Installer
J 44636-1 JD 44636-1 Front Output Shaft Seal Installer
J 44636-2 JD 44636-2 Front Output Shaft Seal Protector
J 42738 JD 42738 Input Shaft Seal Installer

Install the mounting studs 1.16 to 1.20 inch in height.

Fig 1: Installing Mounting Studs
Install the front output shaft bearing.

Fig 2: Installing Front Output Shaft Bearing
Install the front output shaft bearing retaining ring.

Fig 3: Installing Front Output Shaft Bearing Retaining Ring
Install the front output shaft assembly.

Fig 4: Installing Front Output Shaft Assembly
Install the front input shaft retaining ring.

Fig 5: Installing Front Input Shaft Retaining Ring
Install the input shaft bearing.

Fig 6: Installing Input Shaft Bearing
Install the input shaft bearing retaining ring.

Fig 7: Installing Input Shaft Bearing Retaining Ring
Install the input shaft assembly.

Fig 8: Installing Input Shaft Assembly
Install the input shaft bearing retaining ring.

Fig 9: Installing Input Shaft Bearing Retaining Ring
Install the clutch lever assembly.

Fig 10: Installing Clutch Lever Assembly
Install the clutch inserts. See Figure.
Tighten

Tighten the clutch lever inserts to 40 N.m (29 ft lbs)
Install the outer drum on the mainshaft.

Fig 11: Installing Outer Drum On Mainshaft
Install the inner drum.

Fig 12: Installing Inner Drum

Important: When installing the clutch spring, make sure that the fingers of the spring are pointing up non load only.
Install the clutch spring.

Fig 13: Installing Clutch Spring
Install the inner drum retaining ring.

Fig 14: Installing Inner Drum Retaining Ring

Important: When installing the clutch plates, make sure that the inner lip of the backing plate is facing down.
Install the backing plates.

Fig 15: Installing Backing Plates
Install the clutch pack assembly.

Fig 16: Installing Clutch Pack Assembly
Adjust the clutch clearance. Refer to Cleaning and Inspection or Cleaning and Inspection (Clutch Pack Adjustment) .
Using a press, install the inner bearing in the thrust bearing.
Install the thrust bearing in the outer bearing support.

Fig 17: Assembling Inner Bearing, Thrust Bearing & Outer Bearing Support
Install the apply plate.

Fig 18: Installing Apply Plate
Install the apply plate retaining ring.

Fig 19: Installing Apply Plate Retaining Ring
Install the mainshaft assembly.

Fig 20: Installing Mainshaft Assembly

Important: Make sure that the relationship marks used to remove the drive chain and sprockets are aligned for the proper installation.
Install the drive chain and sprockets.

Fig 21: Installing Drive Chain & Sprockets
Install the drive sprocket retaining ring.

Fig 22: Installing Drive Sprocket Retaining Ring
Install the driven sprocket retaining ring.

Fig 23: Installing Driven Sprocket Retaining Ring
Install the oil pump retaining ring.

Fig 24: Installing Oil Pump Retaining Ring
Install the oil pump pick up tube seal.

Fig 25: Installing Oil Pump Pick Up Tube Seal
Install the oil pump assembly.

Fig 26: Installing Oil Pump Assembly
Install the oil pump wave washer.

Fig 27: Installing Oil Pump Wave Washer
Install the magnet.

Fig 28: Installing Magnet
Install the tone wheel.

Fig 29: Installing Tone Wheel
Install the first rear output shaft bearing retaining ring.

Fig 30: Installing First Rear Output Shaft Bearing Retaining Ring
Install the rear output shaft bearing.

Fig 31: Installing Rear Output Shaft Bearing
Install the second rear output shaft bearing retaining ring.

Fig 32: Installing Second Rear Output Shaft Bearing Retaining Ring
Install the oil pump wear sleeve.

Fig 33: Installing Oil Pump Wear Sleeve

Important: Make sure that the sealing surface on the front case half and the rear case half are free of dirt and cleaning solvent.
Apply a small bead of sealant to the front case half (the bead should not be any larger than an 1/8 of an inch in width).

Fig 34: Cleaning Sealing Surface On Front Case Half

Important: Before the rear case half is installed on the mainshaft, make sure that the outer retaining ring for the rear output shaft bearing is in alignment with the access opening.
Insert a pair of snap ring pliers in the access opening.
Using the snap ring pliers, open the outer retaining ring for the rear output shaft bearing.

Fig 35: Opening Outer Retaining Ring For Rear Output Shaft Bearing
Install the rear case half assembly.

Fig 36: Installing Rear Case Half Assembly
Install the retaining bolts.
Tighten

Tighten the retaining bolts to 30 N.m (21 ft lbs)

Fig 37: Installing Rear Case Half Retaining Bolts
Using the J 42738, install the input shaft seal.

Fig 38: Installing Input Shaft Seal

Important: When installing the rear output shaft seal, make sure that the drain hole is facing down.
Using the J 37668-A, install the rear output shaft seal.

Fig 39: Installing Rear Output Shaft Seal
Install the dust seal.

Fig 40: Installing Dust Seal
Install the J 44636-2 on the front output shaft.

Fig 41: Installing Seal Protector Onto Front Output Shaft
Install the front output shaft seal on the J 44636-2.

Fig 42: Installing Front Output Shaft Seal Onto Seal Protector
Using the J 44636-1, install the front output shaft seal.

Fig 43: Installing Front Output Shaft Seal
Install the left rear speed sensor.
Tighten

Fig 44: Installing Rear Speed Sensors

Tighten the left rear speed sensor to 15 N.m (11 ft lbs)
Install the right rear speed sensor.
Tighten

Tighten the right rear speed sensor to 15 N.m (11 ft lbs)
Install the front speed sensor.
Tighten

Tighten the front speed sensor to 15 N.m (11 ft lbs)
Install the vent tube elbow (if needed).

Fig 45: Installing Vent Tube Elbow
Install the motor/encoder gasket.
Install the motor/encoder.
Install the motor/encoder mounting bolts.
Tighten

Tighten the motor/encoder mounting bolts to 20 N.m (14 ft lbs)

Fig 46: Installing Motor/Encoder & Gasket
Install the rubber plug.

Fig 47: Installing Rubber Plug