Steps 1 - 44

Transfer Case Assemble





^ Tools Required
- J 8092 Universal Driver Handle
- J 36371 Output Shaft Bearing Installer
- J 36373 Input Sun Gear Ball Bearing Installer
- J 36850 Transjel Lubricant
- J 37668-A Shaft Seal Installer
- J 42738 Seal Installer
- J 45235 Rear Speed Sensor Reluctor Wheel Installer
- J 45236 Front Output Shaft Seal Installer
- J 45238 Input Gear Thrust Bearing Installer (NVG 226)
- J 45239 Needle Bearing Installer

Assembly Procedure

Important:
^ Install the input gear seal after the transfer case is assembled.
^ Do not cock the bearing when installing. Ensure the bearing is being installed square to the bore.

1. Using a suitable bearing installer, install the rear output shaft bearing. Ensure the bearing installer is used against the outer race of the bearing.





2. Using the J 36371, install the front output shaft rear bearing into the rear case half.





3. Using the J 8092 (1) and the J 45239 (2), install the control actuator lever shaft bearing until it bottoms in the bore. The seal side of the bearing faces the encoder motor.





4. Install the control actuator lever shaft in the rear case half.





5. Install a new control actuator lever shaft retaining ring.





6. Install the oil pump screen and oil pump hose to the oil pump suction pipe.





7. Install a new O-ring seal on to the oil pump Suction pipe.
8. Lightly lubricate the O-ring seal with transfer case oil.
9. Install the oil pump suction pipe assembly in the rear case half. Ensure the oil pump suction pipe is fully seated.





10. Install the chip collector magnet in the rear case half.





11. Apply a thin layer of retaining compound GM P/N United States 12377901, GM P/N Canada 10953504, or equivalent, to the vent, if removed.
12. Tap the vent into the case. Ensure the vent is aligned in the direction shown.





Important: Install the front output shaft sea[ after the transfer case is assembled.

13. Using the J 36371, install the front output shaft front bearing into the front case.





14. Using a press, install the input gear bearing into the front case.
^ Ensure the press plates fit properly on the case.
^ Use a suitable press tool that fits to the bearing outer race.





Important: Apply J 36850 to the thrust washer in order to hold the thrust washer on the planetary gear assembly.

15. Apply a layer of the J 36850 on the large diameter thrust washer.
16. Install the large diameter thrust washer on the planetary gear assembly.





17. Install the planetary gear assembly into the front case. Rotate the planetary gears to align with the annulus gear.





18. Ensure the large diameter thrust washer is aligned to the input gear bearing race.
19. If removed, lightly lubricate the input gear bore seal with transfer case fluid.

Important: The bore seal installation depth should not block the oil gallery hole in the input gear. If installed too far, the transmission output shaft may contact the bore seal.

20. Install a new input gear bore seal into the input gear. Push the bore seal into place by hand until the seal is just past the oil gallery hole in the input gear. Ensure the bore seal is square in the bore.





21. If removed, install the input gear thrust bearing into the input gear using the J 8092 (1) and the J 45238 (2).





Important: Apply J 36850 to the thrust washer in order to hold the thrust washer on the input gear.

22. Apply a layer of J 36850 on to the small diameter thrust washer.
23. Install the small diameter thrust washer on to the input gear.





24. Position the input gear in the planetary gear assembly.
Ensure the thrust washers are in the correct position.
Ensure the input gear and the planetary gears are correctly meshed.





25. Using a press, press the input gear assembly into the input gear bearing.
25.1. Support the front case half on press plates to allow the input gear to protrude.
25.2. Support the inner race of the input gear bearing.
25.3. Use a suitable press plate on the end of the input gear.
25.4. Press on the input gear until fully seated against the input gear bearing.
26. Inspect for proper assembly by turning the input gear. The input gear and planetary gears should turn without roughness or binding. If binding or roughness is present, inspect for debris in the planetary gears or for improper assembly.





27. Install the rear output shaft thrust washer. Align the tabs with the shaft splines.





28. Install a new retaining ring for the clutch housing on the rear output shaft. Ensure the retaining ring is properly installed in the groove.





29. Install the drive sprocket on to the clutch housing.





30. Install a new retaining ring for the drive sprocket on the clutch housing.





31. Lightly lubricate the clutch housing inner bearing with transfer case fluid.
32. Install the clutch housing on to the rear output shaft.





33. Install the clutch hub into the clutch housing.





34. With the friction material facing down, install an outer clutch disc into the clutch housing.





35. With the friction material facing down, install an inner clutch disc into the clutch housing.
36. Continue to install the outer clutch disc and inner clutch disc, alternating until 9 of each are installed.





37. Install a new clutch hub retaining ring on to the rear output shaft.





38. Install the clutch spring.





39. Install the clutch apply plate.
^ Ensure the clutch apply plate tabs are aligned with the clutch hub.
^ Ensure the clutch spring is seated properly in the underside groove of the clutch apply plate.





40. Install the clutch pressure plate bearing. The bearing will only install in one direction. The bearing will fit flush to the inner plate when properly installed.





41. Install the clutch inner plate.





Important: The marks on the clutch pressure plate bearing must be aligned before installing the clutch apply plate retaining ring.

42. Align the markings on the clutch pressure plate bearing.





43. While pushing down on the clutch apply plate, install the clutch apply plate retaining ring.





44. Install the shift fork shaft with the shift detent lever.
44.1. Rotate the control actuator lever shaft while installing to the shift detent lever.
44.2. Ensure the shift detent lever is installed on the roller of the control actuator lever shaft.