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
   Fig 1: Assembling Front Drive Shift Shaft

   
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.
   Fig 2: Installing Input Gear Bearing & Snap Ring

   
7. Use J 37752  in order to install the input gear oil seal into the front case.
   Fig 3: Installing Input Gear Oil Seal

   
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 

   Tighten the oil guide bolt to the 10 N.m (89 in lbs).

10. Use J 35871  and a press arbor in order to install the input gear into the front case.
    Fig 4: Installing Input Gear Into 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.
    Fig 5: Installing Front Output Shaft Bearings

    
13. Use J 37757  in order to install the front output shaft needle bearing into the center case.
    Fig 6: Installing Front Output Shaft Needle Bearing

    
14. Use J 37751  in order to install the front output shaft oil seal into the center case.
    Fig 7: Installing Front Output Shaft Oil Seal

    
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 

    Tighten the case gutter bolt to 12 N.m (106 in 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.
    Fig 8: Installing Rear Output Shaft Front Bearing

    
18. Install the following components onto the rear output shaft (1):
    1. 18.1. The front bearing (2)
    2. 18.2. The low output gear needle bearing (3)
    3. 18.3. The low output gear (4)
    4. 18.4. The reduction clutch hub (5)
    5. 18.5. The snap ring (6)
    Fig 9: Assembling Rear Output Shaft

    
19. Use J 36183  in order to install the rear output shaft into the center case.
    Fig 10: Installing Rear Output Shaft

    
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.
    Fig 11: Press-Fitting Needle Bearing Into Center Case

    
24. Install the interlock ball (1) into the center case passage. Push against the interlock notch of the front drive shift shaft (2).
    Fig 12: Installing Interlock Ball

    

    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.
    Fig 13: Installing Components Onto Rear Output Shaft In Rear Of Center Case

    

    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® pipe sealant GM P/N 1052080 or the equivalent to the threaded portion of the 2 locating screws.
    Fig 14: Installing Components Onto Rear Output Shaft In Front Of Center Case

    
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 

    Tighten the locating screws to 26 N.m (19 ft lbs).

    Fig 15: Installing Components Into Center Case

    
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)
    Fig 16: Assembling Countershaft

    
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
    Fig 17: Installing Countershaft Into Center Case

    
35. Install the front case to the center case. Secure the front case with 9 bolts (1).

    Tighten 

    Tighten the front case bolts to 23 N.m (17 ft lbs).

36. Apply Loctite® 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft plate bolt.
    Fig 18: Installing Front Case To Center Case

    
37. Install the countershaft case plate to the front case.

    Secure the countershaft case plate with 1 bolt (2).

    Tighten 

    Tighten the countershaft case plate bolt to 23 N.m (17 ft lbs).

    Fig 19: Identifying Countershaft Case Plate Bolt

    
38. Use J 37757  in order to install the rear output shaft needle bearing in the rear case.
    Fig 20: Installing Rear Output Shaft Needle Bearing

    
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.
    Fig 21: Installing Rear Output Shaft Oil Seal

    
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)
    Fig 22: Installing Drive Sprocket & Chain

    
42. Install the synchronizer plate (1) to the front output shaft case.
    Fig 23: Installing Synchronizer Plate

    
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.

    Fig 24: Installing Rear Output Shaft Rear Bearing

    
49. Use J 26900-5  and a straightedge in order to measure the rear case bearing bore depth:
    1. 49.1. Place the straightedge (1) across the rear case.
    2. 49.2. Measure the bearing bore depth (2) including the width of the straightedge.
    3. 49.3. Record the measurement.
    Fig 25: Measuring Rear Case Bearing Bore Depth

    

    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.
    Fig 26: Press-Fitting Needle Bearing Into Rear Case

    
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:
    1. 51.1. Measure the height of the rear output shaft bearing.

       Include the width of the straightedge.

    2. 51.2. Record the measurement.

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

    Fig 27: Measuring Height Of Rear Output Shaft Rear Bearing On Rear Output Shaft

    
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® 599 RTV silicone sealer or equivalent to the rear case mating surface.
    Fig 28: Inspecting Rear Case Mating Surfaces

    
56. Install the rear case to the center case. Secure the rear case with 15 bolts.

    Tighten 

    Tighten the rear case bolts to 23 N.m (17 ft lbs).

    Fig 29: Installing Rear Case To Center Case

    
57. Install the reduction shift yoke (1) onto the reduction shift shaft in the rear case.
    Fig 30: Installing Reduction Shift Yoke Onto Reduction Shift Shaft

    
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® 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 

    Tighten the select return spring bolt to 35 N.m (25 ft lbs).

61. Apply Loctite® 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 

    Tighten the gearshift lever case bolts to 16 N.m (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 

    Tighten the speedometer driven gear case retaining bolt to 10 N.m (89 in 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 

    Tighten the four-wheel drive switch to 19 N.m (14 ft lbs).

    Fig 31: Installing Steel Ball & Four-Wheel Drive Switch Into Rear Case

    
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 

    Tighten the four-wheel drive low switch to 19 N.m (14 ft lbs).