Transfer Case Assemble

^ Tools Required
- J 6133-01 Input Gear Bearing Installer
- J 37752 Oil Sea] Installer
- J 35871 Input Gear Installer
- J 35664 Press Tube/Bearing Installer
- J 22912-01 Split Plate
- J 37757 Needle Bearing Installer
- J 37753 Bearing Installer
- J 36183 Output Rear Shaft Installer
- J 39497 Friction Ring Remover and Installer
- J 37751 Oil Seal Installer
- J 36850 Transjel(r) Transmission Assembly Lubricant
- J 26900-5 Vernier Caliper





1. Place the following components onto the front drive shift shaft:
^ The front drive shift shaft C-clip
^ The shaft stop washer
^ The front drive shift fork spring
^ The front drive shift fork
^ The shaft stop washer

2. Tighten the front drive shift shaft C-clip in order to secure the above components to the front drive shift shaft.
3. Install the reduction shift fork onto the reduction shift shaft.
4. Install the reduction shift fork roll pin.
This will secure the reduction shift fork to the reduction shift shaft.





5. Use the J 6133-01 and a press arbor in order to install the input gear bearing onto the input gear.
6. Install the input gear Snap Ring onto the input gear.





7. Use the J 37752 in order to install the input gear oil seal into the front case.
8. Apply Loctite 414 GM P/N 12345493 or equivalent to the threaded portion of the oil guide bolt.
9. Install the oil guide in the rear case.
Secure the oil guide with one bolt.
^ Tighten the oil guide bolt to the 10 Nm (89 inch lbs.).

NOTICE: Refer to Service Precautions in Service Precautions.





10. Use the J 35871 and a press arbor in order to install the input gear into the front case.
11. Install the input gear bearing C-clip onto the input gear.





12. Use the J 35664 with the, J 22912-01 and a press arbor in order to install the front output shaft bearings onto the front output shaft.





13. Use the J 37757 in order to install the front output shaft needle bearing into the center case.





14. Use the J 37751 in order to install the front output shaft oil seal into the center case.
15. Install the case gutter into the center case.
Secure the case gutter with one bolt.
^ Tighten the case gutter bolt to 12 Nm (106 inch lbs.).

16. Use a plastic mallet in order to install the front output shaft into the center case.





17. Use the J 37753 with the J 35664 and a press arbor in order to install the rear output shaft front bearing onto the rear output shaft.





18. Use a J 36183 in order to install the rear output shaft into the center case.
19. Apply J 36850 to the low output gear needle bearing.





20. Install the following components onto the rear output shaft:
20.1. The low output gear needle bearing (1)
20.2. The low output gear
20.3. The reduction clutch hub (2)

21. Install the reduction hub C-clip (3) onto the rear output shaft.
22. Install the interlock ball into the center case passage.
Push against the interlock notch of the front drive shift shaft.
23. Install the following components onto the rear output shaft, in the rear of the center case:
23.1. The front drive shift shaft
23.2. The front drive shift fork
23.3. The front drive clutch sleeve
23.4. The front drive clutch hub

24. Align the marks on the front drive clutch hub and the sleeve.
25. Install the following components onto the rear output shaft, in the front of the center case.
25.1. The reduction shift shaft
25.2. The reduction shift fork
25.3. The reduction clutch sleeve

26. Align the marks on the reduction clutch hub and the sleeve.
27. Apply Loctite 599 RTV silicone sealer or equivalent to the two rubber plugs.
28. Apply a light coat of Loctite pipe sealant GM P/N 1052080 or the equivalent to the threaded portion of the two locating screws.
29. Install the following components into the center case:
^ The two locating balls
^ The two locating springs
^ One rubber plug
^ The two washers
^ The two locating screws
^ Tighten the locating screws to 26 Nm (19 ft. lbs.).





30. Use the J 39497 and a press arbor in order to install the new countershaft friction ring onto the countershaft.

IMPORTANT: Install the friction ring precisely 39.5 mm (1.56 inch) from the end of the countershaft.

31. Install the new countershaft O-ring onto the countershaft.
32. Apply J 36850 to the new countershaft O-ring.
33. Apply J 36850 to the countershaft needle bearings.
34. Install the following components to the countershaft:
34.1. The countershaft spacer
34.2. The countershaft needle bearings
34.3. The counter gear

35. Install the following components to the countershaft:
35.1. The countershaft washer balls
35.2. The washers

36. Install the countershaft assembly into the center case.
37. Apply Loctite 599 RTV silicone sealer or equivalent to the following surfaces:
^ The front case
^ The center case mating surfaces

38. Install the front case to the center case.
Secure the front case with the nine bolts.
^ Tighten the front case bolts to 23 Nm (17 ft. lbs.).

39. Apply Loctite 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft plate bolt.
40. Install the countershaft case plate to the front case.
Secure the countershaft case plate with one bolt.
^ Tighten the countershaft case plate bolt to 23 Nm (17 ft. lbs.).





41. Use the J 37757 in order to install the rear output shaft needle bearing in the rear case.





42. Use the J 37751 in order to install the rear output shaft oil seal into the rear case.
43. Apply J 36850 to the shaft ball in order to retain it in place on the rear output shaft.





44. Install the following components onto the rear output shaft (1) and onto the front output shaft:
44.1. The rear output shaft washer ball
44.2. The drive sprocket (3)
44.3. The drive chain (2)

45. Apply J 36850 to the drive sprocket needle bearing.
46. Install the following components onto the rear output shaft:
^ The drive sprocket needle bearing
^ The drive sprocket bushing





47. Use the J 35664 in order to install the rear output shaft rear bearing onto the rear output shaft.
48. Install the rear output shaft rear bearing C-clip onto the rear output shaft.
49. Install the speedometer drive gear on the output rear shaft.
Secure the speedometer drive gear with the speedometer drive gear C-clip.





50. Use the J 26900-5 and a straightedge in order to measure the rear case bearing bore depth:
50.1. Place the straightedge (1) across the rear case.
50.2. Measure the bearing bore depth (2) including the width of the straightedge.
50.3. Record the measurement.





51. Use the J 26900-5 and a straightedge in order to measure the height of the rear output shaft rear bearing on the rear output shaft:
51.1. Measure the height of the rear output shaft bearing.
Include the width of the straightedge.
51.2. Record the measurement.

52. Subtract the height of the bearing on the rear output shaft from the rear of the case bearing bore depth in order to find the shim clearance.

IMPORTANT: No shim is needed if the shim clearance is 0-0.13 mm (0-0.0005 inch) or less.

53. Select the appropriate shim thickness from the selective shim chart.
Refer to General Specifications.
54. Apply J 36850 to the selective shim in order to retain it in place on top of the rear output shaft rear bearing.
55. Install the selective shim to the top of the rear output shaft rear bearing.





56. Apply Loctite 599 RTV silicone sealer or equivalent to the rear case mating surface.
57. Install the rear case to the center case.
Secure the rear case with the fifteen bolts.
^ Tighten the rear case bolts to 23 Nm (17 ft. lbs.).





58. Install the reduction shift yoke onto the reduction shift shaft in the rear case.
59. Use the reduction shift yoke roll pin in order to secure the reduction shift yoke to the reduction shift shaft.
60. Apply a light coat of Loctite pipe sealant GM P/N 1052080 or equivalent to the threaded portion of the select return spring bolt.
61. Install the following components into the rear case:
^ The select return pin
^ The select return ball and washer
^ The washer
^ The select return spring
^ The select return spring bolt
^ Tighten the select return spring bolt to 35 Nm (25 ft. lbs.).

62. Apply Loctite 599 RTV silicone sealer or equivalent to the following surfaces:
^ The rear case
^ The gearshift lever case mating surfaces

63. Install the gearshift lever case to the rear case.
Secure the gearshift lever case with five bolts.
^ Tighten the gearshift lever case bolts to 16 Nm (12 ft. lbs.).

64. Apply J 36850 to the speedometer driven gear case O-ring.
65. Install the speedometer driven gear case.
Secure the speedometer driven gear case with one bolt.
^ Tighten the speedometer driven gear case retaining bolt to 10 Nm (89 inch lbs.).

66. Inspect the four-wheel drive switch O-ring for cuts or damage.
Replace as necessary.
67. Apply J 36850 to the four-wheel drive switch O-ring.
68. Install the following components into the rear case:
^ The steel ball
^ The four-wheel drive switch
^ Tighten the four-wheel drive switch to 19 Nm (14 ft. lbs.).

69. Inspect the four-wheel drive low switch O-ring for cuts or damage.
Replace as necessary.
70. Apply J 36850 to the four-wheel drive low switch O-ring.
71. Install the steel ball and the four-wheel drive low switch into the rear case.
^ Tighten the four-wheel drive low switch to 19 Nm (14 ft. lbs.).