Transfer Case Assemble

Tools Required

• J 6133-A  Bearing Race Installer. See Special Tools and Equipment  .
• J 37752  Oil Seal Installer. See Special Tools and Equipment  .
• J 35871  Countershaft Front Bearing Installer. See Special Tools and Equipment  .
• J 35664 Press Tube/Bearing Installer
• J 22912-O1 Split Plate
• J 37757  Needle Bearing Installer. See Special Tools and Equipment  .
• J 37753  Bearing Installer. See Special Tools and Equipment  .
• J 36183  Input Shaft Press Tube. See Special Tools and Equipment  .
• J 39497  Friction Ring Remover and Installer. See Special Tools and Equipment  .
• J 37751  Oil Seal Installer. See Special Tools and Equipment  .
• J 36850  Transjel Transmission Assembly Lubricant. See Special Tools and Equipment  .
• J 26900-5 Vernier Caliper

Fig 1: Identifying Front Drive Shaft Components
Courtesy of GENERAL MOTORS CORP.
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.

Fig 2: View Of Input Gear Snap Ring
Courtesy of GENERAL MOTORS CORP.
5. Use J 6133-A  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 3: Identifying J 37752
Courtesy of GENERAL MOTORS CORP.
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.
NOTE: Refer to Fastener Notice in Cautions and Notices.
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 lb in).

Fig 4: Using J 35871 To Install Input Gear
Courtesy of GENERAL MOTORS CORP.
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.
Fig 5: Pressing Front Output Shaft Bearings Onto Front Output Shaft
Courtesy of GENERAL MOTORS CORP.
12. Use J 35664 with J 22912-O1 and a press arbor in order to install the front output shaft bearings onto the front output shaft.
Fig 6: Installing J 37757 Into Center Case
Courtesy of GENERAL MOTORS CORP.
13. Use J 37757  in order to install the front output shaft needle bearing into the center case.
Fig 7: View Of J 37751
Courtesy of GENERAL MOTORS CORP.
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:  Tighten the case gutter bolt to 12 N.m (106 lb in).

16. Use a plastic mallet in order to install the front output shaft into the center case.
Fig 8: Installing The Rear Output Shaft Front Bearing Onto The Rear Output Shaft Using J 37753 & J 35664
Courtesy of GENERAL MOTORS CORP.
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 9: Expanded View Of Reduction Clutch Hub
Courtesy of GENERAL MOTORS CORP.
18. Install the following components onto the rear output shaft (1):
    1. The front bearing (2)
    2. The low output gear needle bearing (3)
    3. The low output gear (4)
    4. The reduction clutch hub (5)
    5. The snap ring (6)
Fig 10: Installing The Rear Output Shaft Into The Center Case Using J 36183
Courtesy of GENERAL MOTORS CORP.
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.
Fig 11: Aligning Needle Bearing Using J 37753
Courtesy of GENERAL MOTORS CORP.
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 12: Locating Interlock Ball In Center Case Passage
Courtesy of GENERAL MOTORS CORP.
24. Install the interlock ball (1) into the center case passage.

    Push against the interlock notch of the front drive shift shaft (2).

Fig 13: Identifying Front Drive Shift Components
Courtesy of GENERAL MOTORS CORP.
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 14: View Of Reduction Shift Components
Courtesy of GENERAL MOTORS CORP.
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(R) 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.
Fig 15: Identifying Center Case Components
Courtesy of GENERAL MOTORS CORP.
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 lb ft).

Fig 16: Countershaft Assembly
Courtesy of GENERAL MOTORS CORP.
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 17: Identifying Countershaft Assembly
Courtesy of GENERAL MOTORS CORP.
33. Install the countershaft assembly (1) into the center case.
34. Apply Loctite(R) 599 RTV silicone sealer or equivalent to the following surfaces:
    • The front case
    • The center case mating surfaces
Fig 18: View Of Front Case Bolts
Courtesy of GENERAL MOTORS CORP.
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 lb ft).

36. Apply Loctite(R) 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft plate bolt.
Fig 19: Locating Countershaft Case Plate Bolt
Courtesy of GENERAL MOTORS CORP.
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 lb ft).

Fig 20: Cross Sectional View Of J 37757
Courtesy of GENERAL MOTORS CORP.
38. Use J 37757  in order to install the rear output shaft needle bearing in the rear case.
Fig 21: Identifying J 37751
Courtesy of GENERAL MOTORS CORP.
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 22: View Of Rear Output Shaft Components
Courtesy of GENERAL MOTORS CORP.
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 23: Locating Synchronizer Plate
Courtesy of GENERAL MOTORS CORP.
42. Install the (1) to the front output shaft case.
43. Apply Loctite(R) 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
Fig 24: Installing Rear Output Shaft Rear Bearing Using J 35664
Courtesy of GENERAL MOTORS CORP.
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 25: Measuring Rear Case Bearing Bore Depth With J 26900-5
Courtesy of GENERAL MOTORS CORP.
49. Use J 26900-5 and a straightedge in order to measure the rear case bearing bore depth:
    1. Place the straightedge (1) across the rear case.
    2. Measure the bearing bore depth (2) including the width of the straightedge.
    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.
Fig 26: Press-Fitting The Needle Bearing Into The Rear Case
Courtesy of GENERAL MOTORS CORP.
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 27: Measuring The Height Of The Rear Output Shaft Rear Bearing On The Rear Output Shaft Using J 26900-5
Courtesy of GENERAL MOTORS CORP.
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. Measure the height of the rear output shaft bearing.

       Include the width of the straightedge.

    2. Record the measurement.
IMPORTANT: No shim is needed if the shim clearance is less than 0.13 mm (0.0005 in).
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.
Fig 28: Identifying Rear Case Mating Surface
Courtesy of GENERAL MOTORS CORP.
55. Apply Loctite(R) 599 RTV silicone sealer or equivalent to the rear case mating surface.
Fig 29: Locating Rear Case Bolts
Courtesy of GENERAL MOTORS CORP.
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 lb ft).

Fig 30: Identifying Reduction Shift Yoke
Courtesy of GENERAL MOTORS CORP.
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:  Tighten the select return spring bolt to 35 N.m (25 lb ft).

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:  Tighten the gearshift lever case bolts to 16 N.m (12 lb ft).

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 lb in).

Fig 31: View Of Four-Wheel Drive Switch & Steel Ball
Courtesy of GENERAL MOTORS CORP.
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 lb ft).

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 lb ft).