3. Transfer Case Assemble

Assembly Procedure





1. Install the seal and sector shaft support.
^ Tighten the sector shaft support to 33 Nm (24 ft. lbs.).





2. Install the select switch.
^ Tighten the select switch to 27 Nm (20 ft. lbs.).





3. Install the front output seal.
4. Install the front input bearing.





5. Install the front input bearing retaining ring.





6. Using J 29162 install the rear seal into the rear case extension area.





7. Position a thrust washer into the planetary gear.
8. Install the input gear into the planetary gear.
9. Position a second thrust washer onto the input gear and inside the planetary gear.
10. Position the carrier ring onto the input gear and inside the planetary gear.





11. Install the carrier lock ring onto the input gear and inside the planetary gear.





12. Install the planetary assembly into the front case half.





13. Install the input gear retaining ring from seal side.





14. Install the front input oil seal.





15. Install the sector assembly.





16. Install the front bearing and the bearing retaining ring onto the front output shaft.





17. Install the front output shaft retaining ring.





18. Install the front output shaft into the front case half. The front output shaft retaining ring on the front output shaft will snap into place and lock the output shaft and front bearing into the front case half.





19. Install the range fork and range shift sleeve assembly.





20. Install the poppet assembly. Note that there are three pieces to the poppet spring:
^ Poppet screw O-ring
^ Poppet spring
^ Poppet plunger





21. Install the synchronizer hub onto the mainshaft.





22. Install the inner cone onto the mainshaft.





23. Install the middle ring onto the mainshaft.





24. Install the outer ring onto the mainshaft.





25. Secure three struts to the synchronizer hub with the retaining ring.
25.1. The hook end of the retaining ring is inserted into the first strut to hold the strut into place.
25.2. Then second and third struts are held in place from in front by the retaining ring.





26. Turn the synchronizer over and install the second retaining ring the same as the first retaining ring was installed.
^ Ensure the hook end of the second retaining ring is not installed into the same strut as the first retaining ring hooked end.
^ Any one of the two remaining struts on the bottom side of the synchronizer hub can be used as the starting point for installation of the hooked end of the retaining ring.





27. Install the clutch sleeve over the synchronizer hub.
^ Ensure the spline of the clutch sleeve is aligned with the strut.
^ Ensure the struts are positioned into the strut pockets (recessed area) of the clutch sleeve.





28. Install the synchronizer assembly onto the mainshaft.





29. Install the retaining ring onto the mainshaft and over the synchronize assembly.
30. Install the synchronize clutch gear. Ensure the gear is installed with the collar side out and the flat side in.





31. Position the shift rail into the mode fork.
32. Position the mode fork and shift rail assembly onto the synchronize clutch sleeve.





33. Installing as one assembly, install the mainshaft, mode fork, and shift rail into the front case.





34. Position the drive and driven sprockets into the chain and onto the main shaft and front output shaft.
34.1. Prior to installation of the drive chain, inspect the chain for three off colored chain link.
34.2. If off colored chain links are found on the drive chain, ensure the chain is installed with the off colored links of the chain positioned toward the rear case.





35. Secure the drive and driven sprockets to the mainshaft and front output shaft with the two retaining rings.





36. Install the rotor O-ring seal onto the mainshaft.





37. Install the oil pump onto the main shaft.
38. Install the oil tube, rubber hose, and oil screen into the front case and onto the oil pump.





39. Install the metal debris magnet.





40. Install the tone wheel onto the mainshaft.
41. Install the tone wheel retaining ring onto the mainshaft.
42. Install the rear output bearing onto the mainshaft. Ensure the retaining ring groove side of the bearing is positioned toward the rear of the case.
43. Install the rear output bearing retaining ring onto the mainshaft.





44. Install the mode fork spring onto the shift rail.





45. Apply RTV sealant GM P/N 12345739 or the equivalent to the mating surfaces of the front and rear case halves.

Important: During the assembly of the front and rear case halves, the rear output bearing retainer ring must be spread open to allow for the case halves to join.

46. While spreading the rear output bearing retainer ring, position the two case halves together.

Notice: Refer to Fastener Notice in Service Precautions.

47. Secure the front and rear cases together with the case bolts.
^ Tighten the case bolts to 37 Nm (27 ft. lbs.).





48. Install the rear output bearing plug.





49. Install the speed sensor.
^ Tighten the speed sensor to 30 Nm (22 ft. lbs.).





50. Install the lever assembly and the sector bolt.
^ Tighten the sector bolt to 27 Nm (20 ft. lbs.).