Steps 1-35

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
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.





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.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the oil guide in the rear case. Secure the oil guide with one bolt.
^ Tighten the oil guide bolt to the 10 Nm (89 inch lbs.).





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.





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.





13. Use J 37757 in order to install the front output shaft needle bearing into the center case.





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 the case gutter bolt to 12 Nm (106 inch 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.





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





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.





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.





24. Install the interlock ball (1) into the center case passage. Push against the interlock notch of the front drive shift shaft (2).





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.





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.





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 the locating screws to 26 Nm (19 ft. lbs.).





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)





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
35. Install the front case to the center case. Secure the front case with 9 bolts (1) .
^ Tighten the front case bolts to 23 Nm (17 ft. lbs.).