Transfer Case Assemble

^ Tools Required
- J 6133-01 Input Gear Bearing Installer
- J 37752 Oil Seal 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 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 (6)
^ The shaft stop washer (5)
^ The front drive shift fork spring (3)
^ The front drive shift fork (4) 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 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 J 37752 in order to install the input gear oil seal into the front case.
8. Apply Loctite(R) 414 GM P/N 12345493 or equivalent to the threaded portion of the oil guide bolt.

Notice: Refer to Fastener Notice in Service Precautions.

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.).





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





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





14. Use J 37751 in order to install the front output shaft oil seal into the center case.
15. Install the case gutters into the center case.
Secure one case gutter with a bolt, and secure the other gutter with a screw.
^ 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 J 37753 with J 35664 and a press arbor in order to install the rear output shaft front bearing onto the rear output shaft.





18. Install the following components onto the rear output shaft (1):
18.1. The front bearing (2)
18.2. The low output gear needle bearing (3)
18.3. The low output gear (4)
18.4. The reduction clutch hub (5)
18.5. The snap ring (6)





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





Important: Do NOT press-fit the bearing further than the limit line. If you press the bearing all the way down to the case bottom, removal of the bearing will be very difficult.

21. Using a press and J 37753, press-fit the needle bearing into the center case (1). Apply a straightedge (2) to the top surface of the case and press-fit until the limit line (4) of J 37753 aligns with the bottom surface of the straightedge.
22. Install the reduction hub C-clip (3) onto the rear output shaft.
23. Install the caged needle bearing.





24. Install the interlock ball (1) into the center case passage. Push against the interlock notch of the front drive shift shaft (2).





Important: During installation, place the front drive shift shaft at the 4WD position.

25. Install the following components onto the rear output shaft, in the rear of the center case:
^ The front drive shift shaft (4)
^ The front drive shift fork (1)
^ The front drive clutch sleeve (2)
^ The front drive clutch hub (3)
26. Align the marks on the front drive clutch hub and the sleeve.





Important: During installation, place the reduction shift shaft at the 4WD position.

27. Install the following components onto the rear output shaft, in the front of the center case.
^ The reduction shift shaft (2)
^ The reduction shift fork (1)
^ The reduction clutch sleeve (3)
28. Align the marks on the reduction clutch hub and the sleeve.
29. Apply Loctite 599 RTV silicone sealer or equivalent to the rubber plug.
30. Apply a light coat of Loctite(R) pipe sealant GM P/N 1052080 or the equivalent to the threaded portion of the 2 locating screws.





31. Install the following components into the center case:
^ The 2 locating balls (2)
^ The 2 locating springs (3)
^ The 1 rubber plug (1)
^ The 1 washer
^ The 2 locating screws (4).
^ Tighten the locating screws to 26 Nm (19 ft. lbs.).





32. Install the following components to the countershaft (4):
^ The countershaft spacer (6)
^ The countershaft needle bearings (5)
^ The counter gear (1)
^ The countershaft washer balls (3)
^ The washers (2)





33. Install the countershaft assembly (1) into the center case.
34. Apply Loctite 599 RTV silicone sealer or equivalent to the following surfaces:
^ The front case
^ The center case mating surfaces





35. Install the front case to the center case.
Secure the front case with 9 bolts (1).
^ Tighten the front case bolts to 23 Nm (17 ft. lbs.).
36. Apply Loctite 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft plate bolt.





37. Install the countershaft case plate to the front case.
Secure the countershaft case plate with 1 bolt (2).
^ Tighten the countershaft case plate bolt to 23 Nm (17 ft. lbs.).





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





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





41. Install the following components onto the rear output shaft (1) and onto the front output shaft:
^ The rear output shaft washer ball
^ The drive sprocket (3)
^ The drive chain (2)





42. Install the synchronizer plate (1) to the front output shaft case.
43. Apply Loctite 414 GM P/N 12345493 or equivalent to the threaded portion of the 2 screws (2). Secure the synchronizer plate with the coated screws.
44. Apply J 36850 to the drive sprocket needle bearing.
45. Install the following components onto the rear output shaft:
^ The drive sprocket needle bearing
^ The drive sprocket bushing





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





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





Important: Do NOT press-fit the bearing further than the limit line. If you press the bearing all the way down to the case bottom, removal of the bearing will be very difficult.

50. Using a press and J 37753 (2), press-fit the needle bearing into the rear case (4). Apply a straightedge (3) to the top surface of the case and press-fit until the limit line (1) of J 37753 aligns with the bottom surface of the straightedge.





51. Use 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.

Important: No shim is needed if the shim clearance is less than 0.13 mm (0.0005 inch).

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.
53. Apply J 36850 to the selective shim in order to retain it in place on top of the rear output shaft rear bearing.
54. Install the selective shim to the top of the rear output shaft rear bearing.





55. Apply Loctite(R) 599 RTV silicone sealer or equivalent to the rear case mating surface.





56. Install the rear case to the center case.
Secure the rear case with 15 bolts.
^ Tighten the rear case bolts to 23 Nm (17 ft. lbs.).





57. Install the reduction shift yoke (1) onto the reduction shift shaft in the rear case.
58. Use the reduction shift yoke roll pin in order to secure the reduction shift yoke to the reduction shift shaft.
59. Apply a light coat of Loctite(R) pipe sealant GM P/N 1052080 or equivalent to the threaded portion of the select return spring bolt.
60. 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.).
61. Apply Loctite(R) 599 RTV silicone sealer or equivalent to the following surfaces:
^ The rear case
^ The gearshift lever case mating surfaces
62. Install the gearshift lever case to the rear case.
Secure the gearshift lever case with 5 bolts.
^ Tighten the gearshift lever case bolts to 16 Nm (12 ft. lbs.).
63. Apply J 36850 to the speedometer driven gear case O-ring.
64. Install the speedometer driven gear case.
Secure the speedometer driven gear case with 1 bolt.
^ Tighten the speedometer driven gear case retaining bolt to 10 Nm (89 inch lbs.).





65. Inspect the four-wheel drive switch O-ring for cuts or damage. Replace as necessary.
66. Apply J 36850 to the four-wheel drive switch O-ring.
67. Install the following components into the rear case:
^ The steel ball (2)
^ The four-wheel drive switch (1).
^ Tighten the four-wheel drive switch to 19 Nm (14 ft. lbs.).
68. Inspect the four-wheel drive low switch O-ring for cuts or damage. Replace as necessary.
69. Apply J 36850 to the four-wheel drive low switch O-ring.
70. 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.).