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Home >> Pontiac >> 2003 >> Vibe Base, FWD, Automatic >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - Vibe (Unit Repair) >> Repair Instructions >> Transfer Case Assemble >> Assembly

Transfer Case Assemble: Assembly

  1. Using a press, install the inner output shaft bearing race in the transfer case.
  2. Using a press, install the outer output shaft bearing race in the transfer case.
    Fig 1: Installing Inner & Outer Shaft Bearing Race
    G01365806Courtesy of GENERAL MOTORS CORP.
  3. Using a press, install the output shaft bearing on the output shaft.
    Fig 2: Installing Output Shaft Bearing
    G01365807Courtesy of GENERAL MOTORS CORP.
  4. Install the output shaft in the transfer case.
    Fig 3: Installing Output Shaft In Transfer Case
    G01365808Courtesy of GENERAL MOTORS CORP.
  5. Install the output shaft spacer on the output shaft.
  6. Install the outer output shaft bearing.
    Fig 4: Installing Output Shaft Spacer & Bearing
    G01365809Courtesy of GENERAL MOTORS CORP.

    Important: 

    Do not tighten the nut until the final adjustment of the preload, tooth contact and backlash is completed.

    NOTE: FASTENER NOTICE in Cautions and Notices.
  7. Using J 46003  and J 46001  , install a new output shaft lock nut.

    Tighten 

    Tighten to 295-403 N.m (218-297 lb ft).

    Fig 5: Installing Output Shaft Lock Nut Using J 46003 & J 46001
    G01365810Courtesy of GENERAL MOTORS CORP.

    Important: 

    If the preload is not within specification, tighten the lock nut in 5-10 degree increments until the correct preload is obtained. If the preload is more than specified, install a new spacer.

  8. Using J 46003  and a torque wrench, measure the output shaft preload.

    Preload 

    Output shaft preload at starting with a new bearing should be 0.52-0.97 N.m (4.6-8.6 lb in) shaft preload at starting with a reused bearing should be 0.30-0.52 N.m (2.7-4.6 lb in).

    Fig 6: Measuring Output Shaft Preload Using Torque Wrench
    G01365811Courtesy of GENERAL MOTORS CORP.
  9. Clean the contact surface of the ring gear and the ring gear mounting case.
  10. Heat the ring gear in boiling water (1) for 10 minutes.
  11. Carefully remove the ring gear from the boiling water.
  12. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the mounting case.
    Fig 7: Heating Ring Gear In Boiling Water
    G01365812Courtesy of GENERAL MOTORS CORP.
  13. Align the marks on the ring gear and mounting case.
  14. Allow the ring gear to cool before tightening the bolts.
  15. Install the 10 bolts.
  16. Tighten the bolts in a diagonal pattern.

    Tighten 

    Tighten the bolts to 78 N.m (57 lb ft).

    Fig 8: Aligning Marks On Ring Gear & Mounting Case
    G01365813Courtesy of GENERAL MOTORS CORP.
  17. Using a press, install the right bearing (1) on the mounting case.
    Fig 9: Identifying Right Bearing On Mounting Case
    G01365814Courtesy of GENERAL MOTORS CORP.
  18. Using a press, install the left bearing on the mounting case.
    Fig 10: Installing Left Bearing On Mounting Case
    G01365815Courtesy of GENERAL MOTORS CORP.
  19. Using a press, install the left mounting case outer bearing race in the transfer case.
    Fig 11: Installing Left Mounting Case Outer Bearing Race
    G01365816Courtesy of GENERAL MOTORS CORP.
  20. Apply gear oil the ring gear mounting case bearings.
  21. Install the ring gear mounting case in the transfer case.
    Fig 12: Installing Ring Gear Mounting Case In Transfer Case
    G01365817Courtesy of GENERAL MOTORS CORP.
  22. Align the spacer with hole in the case.
  23. Install the spacer.
    Fig 13: Aligning Spacer With Hole In Case
    G01365818Courtesy of GENERAL MOTORS CORP.
  24. Using a brass bar and hammer, install the ring gear mounting case washer.
    Fig 14: Installing Ring Gear Mounting Case Washer
    G01365819Courtesy of GENERAL MOTORS CORP.
  25. Install the bearing cap and bolts.
  26. Tighten the bolts

    Tighten 

    Tighten the bolts to 63 N.m (47 lb ft).

    Fig 15: Installing Bearing Caps & Bolts
    G01365820Courtesy of GENERAL MOTORS CORP.

    Important: 

    Backlash should be checked in 3 different positions on the ring gear.

  27. Using a dial indicator, check the backlash of the ring gear.

    Backlash 

    Backlash should be 0.10-0.15 mm (0.0039-0.0059 in).

    Fig 16: Checking Ring Gear Backlash Using Dial Indicator
    G01365821Courtesy of GENERAL MOTORS CORP.
  28. If the backlash is not within the specified value, replace the ring gear mounting case left bearing side washer. For ring gear backlash shim selection, refer to General Specifications .
    Fig 17: Locating Ring Gear Mounting Case Left Bearing Side Washer
    G01365822Courtesy of GENERAL MOTORS CORP.
  29. Coat the teeth of the ring gear with Gear Marking Compound GM P/N 1052351 (Canadian P/N 10953497).
  30. Rotate the ring gear.
  31. Inspect the ring gear contact pattern. Refer to Gear Tooth Contact Pattern Inspection .
    Fig 18: Applying Gear Marking Compound To Ring Gear Teeth
    G01365823Courtesy of GENERAL MOTORS CORP.
  32. If the gear tooth contact pattern is incorrect, replace the output shaft shim. Refer to Output Shaft Shim Selection Chart in General Specifications .
    Fig 19: Locating Output Shaft Shim
    G01365824Courtesy of GENERAL MOTORS CORP.
  33. Using J 46003  (1) and a torque wrench, measure the output shaft preload.

    Preload 

    Output shaft total preload with a new bearing should be 0.3-0.45 N.m (2.7-4.0 lb in). Output shaft preload at starting with a reused bearing should be 0.19-0.33 N.m (1.7-2.9 lb in).

    Fig 20: Measuring Output Shaft Total Preload Using Torque Wrench
    G01365825Courtesy of GENERAL MOTORS CORP.
  34. If output shaft total preload in not within specification, replace the shim. Refer to Preload Shim Selection Chart in General Specifications .
    Fig 21: Locating Output Shaft Preload Shim
    G01365826Courtesy of GENERAL MOTORS CORP.

    Important: 

    Do not tighten the nut until the final adjustment of the preload, tooth contact and backlash is completed.

  35. Using J 46003  and J 46001  , tighten the output shaft lock nut.

    Tighten 

    Tighten to 295-403 N.m (218-297 lb ft).

    Fig 22: Tightening Output Shaft Lock Nut
    G01365827Courtesy of GENERAL MOTORS CORP.
  36. Using a chisel and a hammer, stake the output shaft retaining nut.
    Fig 23: Staking Output Shaft Retaining Nut
    G01365828Courtesy of GENERAL MOTORS CORP.
  37. Install the right wheel drive shaft oil seal to a depth of 33.7-34.3 mm (1.328-1.350 in).
    Fig 24: Installing Right Wheel Drive Shaft Oil Seal
    G01365829Courtesy of GENERAL MOTORS CORP.
  38. Install the left wheel drive shaft oil seal to a depth of 9.7-10.3 mm (0.382-0.406 in).
    Fig 25: Installing Left Wheel Drive Shaft Oil Seal
    G01365830Courtesy of GENERAL MOTORS CORP.
  39. Install the output shaft oil seal to a depth of 1.1-1.9 mm (0.043-0.075 in).
    Fig 26: Installing Output Shaft Oil Seal
    G01365831Courtesy of GENERAL MOTORS CORP.
  40. Using a press, install the dust deflector to the extension housing.
  41. Remove the old sealant from the transfer case extension housing mating surface.
  42. Remove the old sealant from the extension housing mating surface.
    Fig 27: Installing Dust Deflector To Extension Housing
    G01365832Courtesy of GENERAL MOTORS CORP.
  43. Apply a 1.2 mm (0.047 in) bead of silicone sealant GM P/N 12346240 (Canadian P/N 0953493) to the extension housing.
    Fig 28: Identifying Sealant Areas On Extension Housing
    G01365833Courtesy of GENERAL MOTORS CORP.
  44. Install the extension housing and 4 bolts to the transfer case.

    Tighten 

    Tighten the 4 bolts to 26 N.m (19 lb ft).

    Fig 29: Locating Extension Housing Bolts
    G01365834Courtesy of GENERAL MOTORS CORP.
  45. Using a soft faced hammer, install the alignment pins until a height (A) of 10-11 mm (0.393-0.433 in) is obtained.
    Fig 30: View Of Correct Alignment Pin Height
    G01365835Courtesy of GENERAL MOTORS CORP.
  46. Using a soft faced hammer, install the alignment pins until a height (B) of 6.5-7.5 mm (0.256-0.295 in) is obtained.
    Fig 31: Identifying Correct Alignment Pin Height
    G01365836Courtesy of GENERAL MOTORS CORP.
  47. Install the damper and 3 bolts to the transfer case.

    Tighten 

    Tighten the 3 bolts to 26 N.m (19 lb ft).

  48. Install the transfer case breather plug.
  49. Install the transfer case breather oil deflector on the transfer case cover.
    Fig 32: View Of Damper Retaining Bolts
    G01365837Courtesy of GENERAL MOTORS CORP.
  50. Remove the old sealant from the transfer case cover mating surfaces.

    Important: 

    The silicone sealant should be allowed to cure for 1 hour or more before filling with fluid.

  51. Apply a 1.2 mm (0.047 in) bead of silicone sealant GM P/N 12346240 (Canadian P/N 10953493) to the transfer case cover.
    Fig 33: Identifying Sealant Application Areas On Transfer Case Cover
    G01365838Courtesy of GENERAL MOTORS CORP.
  52. Install the transfer case cover and the 8 bolts.

    Tighten 

    Tighten the 8 bolts to 20 N.m (14 lb ft).

    Fig 34: View Of Transfer Case Cover & Bolts
    G01365839Courtesy of GENERAL MOTORS CORP.
  53. Install the transfer case drain plug with a new gasket.

    Tighten 

    Tighten the drain plug to 49 N.m (36 lb ft).

    Fig 35: Locating Transfer Case Drain Plug
    G01365840Courtesy of GENERAL MOTORS CORP.
  54. Install the No.2 transfer case plug with a new gasket.

    Tighten 

    Tighten the drain plug to 49 N.m (36 lb ft).

    Fig 36: Identifying No.2 Transfer Case Plug
    G01365841Courtesy of GENERAL MOTORS CORP.
  55. Install the No.1 transfer case plug with a new gasket.

    Tighten 

    Tighten the drain plug to 49 N.m (36 lb ft).

  56. Install the transfer case mounting studs.

    Tighten 

    Tighten the mounting studs to 39 N.m (29 lb ft).

    Fig 37: Locating No.1 Transfer Case Plug
    G01365842Courtesy of GENERAL MOTORS CORP.
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