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Transfer Case Assemble

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Tools Required

    Fig 1: View Of Transfer Case Mounting Stud
    GM819661Courtesy 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 Front Transfer Case Bench Mount
    GM819573Courtesy of GENERAL MOTORS CORP.
  2. Attach the J 45759  to the front transfer case using the adapter studs. See Special Tools . All of the assembly procedures can be performed with the case mounted to the J 45759  . See Special Tools .
  3. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin. See Special Tools .
    4. Fig 3: View Of Front Case Vent
    GM819664Courtesy 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.

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

    6. Fig 4: View Of Input Shaft Bearing
    GM833018Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate all of the bearings and bearing journals with transfer case fluid during installation.
  6. 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.
    7. Fig 5: Aligning Brass Drift On Outer Bearing Race
    GM819641Courtesy of GENERAL MOTORS CORP.
  7. 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.
    8. Fig 6: View Of Front Output Shaft Cup Plug
    GM819644Courtesy of GENERAL MOTORS CORP.
  8. 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.
    9. Fig 7: View Of Front Output Shaft Assembly
    GM833012Courtesy of GENERAL MOTORS CORP.
  9. Install the front output shaft assembly.
    10. Fig 8: Identifying Input Shaft
    GM833010Courtesy of GENERAL MOTORS CORP.
  10. Install the input shaft.
    11. Fig 9: Locating Drive Chain & Sprockets
    GM833007Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If using the chain and sprockets again, ensure to align the marks of the drive chain and sprockets.
  11. Install the drive chain and sprockets. The blue link on the chain faces up.
    12. Fig 10: View Of Front Sun Gear
    GM833005Courtesy of GENERAL MOTORS CORP.
  12. Install the front sun gear.
    13. Fig 11: Aligning Marks On Pinion Gears
    GM819646Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The planetary differential gears are timed to the sun gears. If the gears are not timed properly, the differential will not rotate without binding.
  13. 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.
    14. Fig 12: Identifying Planetary Differential Assembly
    GM833004Courtesy of GENERAL MOTORS CORP.
  14. Install the planetary differential assembly.
    • Do not rotate the planetary differential pinion gears when installing.
    • Ensure the alignment marks are still in position.
    15. Fig 13: View Of Sun Gear Thrust Washer
    GM833003Courtesy of GENERAL MOTORS CORP.
  15. Lubricate the sun gear thrust washer with J 36850  or equivalent. See Special Tools .
  16. Install the sun gear thrust washer.
    17. Fig 14: Aligning Sun Gear
    GM833002Courtesy of GENERAL MOTORS CORP.
  17. Install the rear sun gear.
    • The shoulder side of the gear faces up.
    • Do not rotate the planetary pinion gears.
    18. Fig 15: Checking Planetary Differential Pinion Gear Rotation
    GM833020Courtesy of GENERAL MOTORS CORP.
  18. Temporarily install the rear output shaft to the planetary differential and the rear sun gear.
  19. 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.
  20. Remove the rear output shaft without disturbing the rear sun gear.
    21. Fig 16: View Of Front Output Shaft Rear Bearing
    GM819637Courtesy of GENERAL MOTORS CORP.
  21. 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.
    22. Fig 17: Using J 22912-01 To Install Rear Output Shaft Bearing
    GM819638Courtesy of GENERAL MOTORS CORP.
  22. Using a hydraulic press and the J 22912-01  , 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.
    23. Fig 18: Identifying Rear Output Shaft Bearing Retaining Ring
    GM819634Courtesy of GENERAL MOTORS CORP.
  23. Install a NEW retaining ring for the rear output shaft bearing.
    24. Fig 19: View Of Input Shaft Rear Support Bushing & Special Tools
    GM1708329Courtesy of GENERAL MOTORS CORP.
  24. Using the J 42176  (1) and the J 45757  (2), install the input shaft rear support bushing in the rear output shaft. See Special Tools .
    25. Fig 20: View Of Rear Output Shaft In The Rear Case Half
    GM819630Courtesy of GENERAL MOTORS CORP.
  25. 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.
    26. Fig 21: Identifying Mating Surfaces On Case Half
    GM833025Courtesy 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 case halves.
  26. Install the locating pins in the front case and rear case half, if necessary.
  27. 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.
    28. Fig 22: View Of Rear Case Half & Front Case Half
    GM819587Courtesy of GENERAL MOTORS CORP.
  28. Lower the rear case half into place.

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

    29. Fig 23: View Of Transfer Case Bolts
    GM819583Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  29. Inspect the nylon coating on the case bolts for cuts or tears.
  30. Replace the case bolts if there is any damage to the nylon coating.
    31. IMPORTANT: The case bolts are self-tapping; they must be hand started. Do not use power assisted tools to install the bolts.
  31. Install the case bolts, the washers, and the brackets.

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

    32. Fig 24: Installing Rear Output Shaft Seal Using J 45756
    GM833029Courtesy of GENERAL MOTORS CORP.
  32. Using J 45756  , install the rear output shaft seal. See Special Tools .
    33. Fig 25: View Of Transfer Case Drain Plug
    GM823193Courtesy of GENERAL MOTORS CORP.
  33. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
  34. Install the drain plug and the fill plug.

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

    35. Fig 26: Installing Front Output Shaft Seal Using J 43484 & J 8092
    GM819655Courtesy of GENERAL MOTORS CORP.
  35. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal. See Special Tools .
    36. Fig 27: Installing Input Shaft Seal Using J 42738
    GM819657Courtesy of GENERAL MOTORS CORP.
  36. Using the J 42738  , install the front input shaft seal. See Special Tools .
  37. Remove the transfer case from the J 45759  . See Special Tools .
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