Assembly Procedure

Tools Required 

• J 3289-20  Holding Fixture
• J 5590  Pinion Bearing Race Installer - Rear
• J 8092  Universal Driver
• J 22828  Input and Countershaft Race Installer
• J 36373  Input Sun Gear Ball Bearing Installer
• J 36850  Transjel Lubricant
• J 42176  Universal Driver Handle - Non-Threaded
• J 43484  Front Output Shaft Seal Installer
• J 45540  Tone Ring and Bearing Installer
• J 45756  Rear Output Shaft Seal Installer
• J 45758  Input Seal Installer
• J 45759  Assembly Fixture
• J 45848  Bearing Installer

1. If removed, install the transfer case mounting studs.

   Tighten 

   Tighten the mounting studs to 31 N.m (23 lb ft).

   Fig 1: Installing Transfer Case Mounting Studs

   Courtesy of GENERAL MOTORS CORP.
2. Attach the J 45759  (2) to the front case half using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759  (2).
3. Install the J 45759  (2) into the J 3289-20  (1) and secure with pivot pin.
   Fig 2: Installing J 45759 To J 3289-20

   Courtesy of GENERAL MOTORS CORP.
4. If removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
5. Install the vent.

   Tighten 

   Tighten the vent to 6 N.m (53 lb in).

   Fig 3: Installing Transfer Case Vent

   Courtesy of GENERAL MOTORS CORP.
6. Install the front output shaft rear bearing in the rear case half.
   • Use a hammer and a brass drift only on the outer bearing race.
   • Ensure the bearing is kept square to the bore while installing.
   Fig 4: Installing Front Output Shaft Rear Bearing

   Courtesy of GENERAL MOTORS CORP.

   Important: 

   Lubricate all bearings and bearing journals with transfer case fluid during installation.

7. Install the input shaft bushing in the front case half using the J 36373  and a hammer.
   Fig 5: Installing Input Shaft Bushing Using J 36373

   Courtesy of GENERAL MOTORS CORP.
8. Install the front bearing for the front output shaft in the front case half.
   • Use a hammer and a brass drift only on the outer bearing race.
   • Ensure the bearing is kept square to the bore while installing.
   Fig 6: Installing Front Output Shaft Front Bearing

   Courtesy of GENERAL MOTORS CORP.
9. If removed, install the input shaft rear support bearing in the rear output shaft using J 42176  (1) and J 45848  (2).
   Fig 7: Installing Input Shaft Rear Support Bearing

   Courtesy of GENERAL MOTORS CORP.
10. Using the J 22828  and a hydraulic press, install the rear output shaft bearing with the retaining ring groove towards the gear.
    Fig 8: Installing Rear Output Shaft Bearing

    Courtesy of GENERAL MOTORS CORP.
11. Using the J 22828  and a hydraulic press, install a NEW speed reluctor wheel.
    Fig 9: Installing Speed Reluctor Wheel

    Courtesy of GENERAL MOTORS CORP.
12. Install a NEW retaining ring for the rear output shaft bearing.
    Fig 10: Installing Rear Output Shaft Bearing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
13. Install the rear output shaft in the annulus gear.
    Fig 11: Installing Rear Output Shaft In Annulus Gear

    Courtesy of GENERAL MOTORS CORP.
    CAUTION: The vehicle could roll while in park if the annulus gear becomes disengaged from the rear output shaft. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.
    NOTE: Damage may occur to the viscous coupling if the retaining ring for the rear output shaft to the annulus gear fails or becomes dislodged during vehicle operation. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.
14. Install a NEW annulus gear retaining ring.
    Fig 12: Installing Annulus Gear Retaining Ring

    Courtesy of GENERAL MOTORS CORP.

    Important: 

    Depending on the build date of the transfer case, it may have a rear output shaft bearing with or without a retaining ring groove. In early build transfer cases, the retaining ring (1) for the rear output shaft bearing was in front of the bearing (2). In later build transfer cases, the retaining ring (3) was moved rearward 5 mm (0.197 in) in the case. The bearings (4) have a groove and the retaining ring is installed in the groove. The service bearings will all have the retaining ring groove, work in both the early build and later build transfer cases. When servicing an early build transfer case with the groove bearing, ensure the retaining ring is installed in front of the bearing and not in the groove.

15. Install the rear output shaft in the rear case.
    • Spread the rear output shaft in rear bearing outer retaining ring.
    • Using a soft-faced hammer, tap on the rear output shaft.
    Fig 13: Identifying Types Of Rear Output Shaft Bearing Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
16. Install the input shaft in the front case.
    Fig 14: Installing Input Shaft In Front Case

    Courtesy of GENERAL MOTORS CORP.
17. Install the viscous coupling on the sun gear.
    Fig 15: Installing Viscous Coupling On Sun Gear

    Courtesy of GENERAL MOTORS CORP.
18. Install the drive gear on the sun gear.
    Fig 16: Installing Drive Gear On Sun Gear

    Courtesy of GENERAL MOTORS CORP.
19. Using a hammer with the J 45540  (2) and the J 5590  (1), install the bearing on the sun gear. Ensure the bearing is fully seated against the drive gear.
    Fig 17: View Of J 45540 & J 5590

    Courtesy of GENERAL MOTORS CORP.
20. Install the sun gear, with the drive gear and the viscous coupling, on the input gear.
    Fig 18: Installing Sun Gear

    Courtesy of GENERAL MOTORS CORP.
21. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver. Install the cup plug 1 mm (0.039 in) from with the end of the shaft.
    Fig 19: Installing Cup Plug In Front Output Shaft

    Courtesy of GENERAL MOTORS CORP.

    Important: 

    Ensure to align the marks of the drive chain and sprockets, if using the chain and sprockets again.

22. Install the drive chain on the drive sprocket.
    • The blue link on the chain faces up.
    • Align the chain, if using it again, with the alignment marks made during disassembly.
      Fig 20: Installing Driven Sprocket

      Courtesy of GENERAL MOTORS CORP.
23. Install the driven sprocket and the chain.
    Fig 21: Installing Driven Sprocket & Chain

    Courtesy of GENERAL MOTORS CORP.
24. Install the front output shaft in the driven sprocket and the bearing.
    Fig 22: Installing Front Output Shaft

    Courtesy of GENERAL MOTORS CORP.
25. Lubricate the sun gear thrust washer with J 36850  or equivalent.
26. Install the sun gear thrust washer.
    Fig 23: Installing Sun Gear Thrust Washer

    Courtesy of GENERAL MOTORS CORP.
27. Install the planetary carrier assembly.
    Fig 24: Installing Planetary Carrier Assembly

    Courtesy of GENERAL MOTORS CORP.
28. Lubricate the sun gear thrust washer with J 36850  or equivalent.
29. Install the planetary carrier thrust washer.
    Fig 25: Installing Planetary Carrier Thrust Washer

    Courtesy of GENERAL MOTORS CORP.

    Important: 

    • Ensure that both the sealing surfaces on the front and rear case halves are free of dirt, oil, and cleaning solvent.
    • Ensure the locating pins are installed in the front case half.
30. Install the locating pins in the front case, if necessary.
31. Apply a 3.175 mm (1/8 in) bead of RTV Sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.
    Fig 26: Identifying Sealant Areas On Front Case Half

    Courtesy of GENERAL MOTORS CORP.
32. Lower the rear case half into place.
    Fig 27: Installing Case Halves Together

    Courtesy of GENERAL MOTORS CORP.
33. Install the case bolts, the washers, and the brackets.

    Tighten 

    Tighten the case bolts to 21 N.m (15 lb ft).

    Fig 28: Installing Case Bolts

    Courtesy of GENERAL MOTORS CORP.
34. Using the J 45756,  install the rear output shaft seal.
    Fig 29: Installing Rear Output Shaft Seal

    Courtesy of GENERAL MOTORS CORP.
35. Install the vehicle speed sensor with a NEW  O-ring seal.

    Tighten 

    Tighten the speed sensor to 17 N.m (13 lb ft).

    Fig 30: Installing Vehicle Speed Sensor

    Courtesy of GENERAL MOTORS CORP.
36. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
37. Install the drain plug and the fill plug.

    Tighten 

    Tighten the drain plug and fill plug to 25 N.m (18 lb ft).

    Fig 31: Installing Drain Plug

    Courtesy of GENERAL MOTORS CORP.
38. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal.
    Fig 32: View Of J 43484 & J 8092

    Courtesy of GENERAL MOTORS CORP.
39. Using the J 45758,  install the front input shaft seal.
40. Remove the transfer case from the J 45759. 
    Fig 33: Installing Front Input Shaft Seal

    Courtesy of GENERAL MOTORS CORP.