Transfer Case Assemble

Transfer Case Assemble

Tools Required

* DT 46429 Oil Seal Driver
* DT 46512 Seal Installer
* EN 46342 Driver Handle
* J 44873 Pinion Flange Holder and Remover




1. Lubricate all internal components with GM P/N 12578261 (Canadian P/N 10953455) prior to assembly.
2. Use the EN 46342 (1) and the DT 46429 (2) in order to install the bearing (207) and seal (301).




3. Install the output shaft (201) with bearing, NEW collapsible spacer (204) and washers (215). Note the proper installation direction of the spacer (204).




4. Lubricate the threads of the output shaft with GM P/N 12378261 (Canadian P/N 10953455).
5. Install the output yoke (208), NEW O-ring (302), NEW sealing washer (303), NEW washer (209), and NEW locknut (210).




6. Secure the case in a soft-jaw vise.

Notice: Refer to Fastener Notice.

7. Install the J 44873 and bolts.

Tighten the bolts to 48 N.m (35 lb ft).

Important: Rotate the output yoke several times in both directions to seat the tapered roller bearings prior to measuring the rotating torque.

8. Tighten the locknut to 108-294 N.m (75.6-217 lb ft) while measuring the rotating torque. Tighten the nut to achieve a rotating torque of 1.15-1.71 N.m (10.2-15.1 lb in).
* If the rotating torque exceeds 1.71 N.m (15.1 lb in), replace the collapsible spacer and assemble again.
* If the locknut tightening torque exceeds 294 N.m (217 lb ft), replace the collapsible spacer and assemble again.
9. Remove the J 44873 and bolts.




10. Stake the locknut using a 3.5 mm (0.138 in) punch.




11. Install the input gear (214) with shim (216) and bearing (217) into the case.




12. Using the EN 46342 (1) and the DT 46512 (2), install the oil seal into the cover. Install the seal until the flat surface of the seal measures 0.00-1.0 mm (0.00-0.04 in) flush with or slightly above the surface of the cover (a).




13. Install a NEW O-ring (304) to the cover.
14. Install the cover (101) and bolts (102).

Tighten the bolts to 26 N.m (20 lb ft).

15. Install the locating pin (105).




16. Install the fill plug (401) and NEW washer (402).
17. Install the drain plug (403) and NEW washer (404).

Tighten the drain plug to 44 N.m (33 lb ft).




18. Install the ventilation valve (408), hose (407), and clamps (406).
19. Inspect the unit for proper assembly.