Part 1

Transfer Case Assemble

^ Tools Required
- J 5590 Crankshaft Sprocket Installer
- J 8001 Dial Indicator Set
- J 36797-A Seal Installer
- J 44752 Bearing, Race, and Seal Installer
- J 44753 Bearing and Seal Installer
- J 44755 Holding Fixture
- J 44757 Shim Selection Kit
- J 44907 Bearing Installer
- J 44908 Bearing Race Installer

Important:
^ The transfer case is assembled for proper gear tooth clearances, backlash, and bearing preloads with selective shims.
^ Do not assemble the internal components dry. Lightly lubricate the bearing races, bearings, gears, and oil seals with the proper lubricant. Components in the transaxle portion of the transfer case should be lubricated with DEXRON III GM P/N 12378470 (Canadian P/N 10952622) or equivalent. Components in the hypoid gear portion of the transfer case should be lubricated with GM P/N 12378514 (Canadian P/N 88901045).

Differential Carrier Assembly

Differential Carrier Assembly:

1. Install the needle bearings (4 and 6) and washer (5) to the gear (3), if required.
2. Install the pin (9), gear (3), and washers (1, 2, 7, and 8) to the differential carrier, if required.
3. Install the ring (10) to the carrier, if required.





4. Install the side gears (2), pinion gears (3), and washers (1 and 4) to the carrier, if required.





5. Install the shaft (1) and roll pin (2) to the carrier, if required.





6. Important: A comma is to be considered a decimal point.

Determine if the driveshaft has a plus, minus, or zero value (1) etched onto the end of the gear. If the driveshaft has a plus, minus, or zero value etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure A.





7. Determine if the driveshaft has a 4 digit measured value (1) etched onto the end of the gear. If the driveshaft has a four-digit number etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure B.

Extension Housing Assembly and Shim Selection - Procedure A





1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.





2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.





3. Measure the distance between the flange on the driveshaft and the end of the pinion. Record the value as dimension B.





4. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft.





5. Install the driveshaft (3) and NEW spacer (1) into the extension housing (2).





6. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.





7. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).





8. Lightly lubricate the splines of the driveshaft with grease.
9. Install the flange (1) onto the shaft using a hydraulic press.





10. Notice: Refer to Fastener Notice in Service Precautions.

Install the extension housing assembly (3) and bolts (1) to the J 44755 (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





11. Install a new nut (1) onto the shaft.
^ Tighten the nut, with new bearings to 250 Nm (185 ft. lbs.).
^ Tighten the nut, with used bearings to 200 Nm (148 ft. lbs.).

12. Remove the extension housing assembly and bolts from the J 44755.





13. Important: Loosening the pinion nut to achieve proper rotating torque requires replacement with a new spacer.

Measure in both directions, the rotating torque of the driveshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 Nm (13 inch lbs.). When reusing driveshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.





14. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.





15. Install the J 44757-3 (2) into the bore of the housing (1).





16. Install J 44757-9 (3) and bolts (2) to the housing (1).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 inch). Record the value as dimension D.





18. Determine if the driveshaft has a plus, minus, or zero value etched onto the end of the gear. Note that the handwritten 1 (1) and 7 (2) are similar. The 7 (2) will have a line drawn through the number. A comma is to be considered a decimal point.
19. Calculate the extension housing shim thickness. Refer to the Extension Housing Shim Calculation Table - Procedure A.

Extension Housing Assembly and Shim Selection - Procedure B





1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.





2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.





3. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft.





4. Install the driveshaft (3) and NEW spacer (1) into the extension housing (2).





5. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.





6. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).





7. Lightly lubricate the splines of the driveshaft with grease.
8. Install the flange (1) onto the shaft using a hydraulic press.





9. Notice: Refer to Fastener Notice in Service Precautions.

Install the extension housing assembly (3) and bolts (1) to the J 44755 (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





10. Install a new nut (1) onto the shaft.
^ Tighten the nut, with new bearings to 250 Nm (185 ft. lbs.).
^ Tighten the nut, with used bearings to 200 Nm (148 ft. lbs.).

11. Remove the extension housing assembly and bolts from the J 44755.





12. Measure in both directions, the rotating torque of the driveshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 Nm (13 inch lbs.). When reusing driveshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.





13. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.





14. Determine the 4 digit value (1) on the end of the driveshaft gear.A comma is to be considered a decimal point. Record the value as dimension E.





15. Install the J 44757-3 (2) into the bore of the housing (1).





16. Install J 44757-9 (3) and bolts (2) to the housing (1).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 inch). Record the value as dimension D.
18. Calculate the extension housing shim thickness. Refer to Extension Housing Shim Calculation Table - Procedure B.

Gears and Cases Assembly





1. Use the J 5590 (1) and a hydraulic press in order to install the bearings onto the idler gear.





2. Use the J 44752 (1) and a hydraulic press in order to install the bearing race into the left cover.





3. Install the idler gear (2) and bearing race (1) to the left case.





4. Inspect the gear for proper installation. The side of the gear with the long flange area (1) should be installed to the right case side.





5. Install the J 44757-1 (1) to the idler gear and race.





6. Install the right cover (1), bolts (2), and J 44757-8 (3) to the left case.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





7. Using a feeler gage, measure the gap (1) in the J 44757-1. The measured amount is the idler gear bearing shim thickness.
8. Disassemble the right case and tools from the left case.





9. Install the selected idler gear bearing shim (2) and bearing race (1) to the right case.





10. Use the J 44752 (1) and a hydraulic press in order to install the bearing race to the right case.





11. Install the driveshaft bearing (3) to the right case.





12. Use the J 44753 (1) and a hydraulic press in order to install the bearing to the right case.





13. Use the J 44753 (1) to install the transaxle side oil seal (2) to the left case. Install until the seal bottoms in the left case bore.





14. Use the J 44753 (1) to install the oil seal-gear oil side (2) to the left case. Install until the tool bottoms against the left case.





15. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the left case.





16. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the left case.





17. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft.





18. Important: The J 44757-7 shim is installed to create measurable end play and to assist in determining the proper size shim for bearing preload.

Assemble the shaft (1), J 44757-7 shim (2), and bearing (3) to the left case.





19. Use the J 5590 (1) and a hydraulic press in order to install the shaft, J 44757-7 shim, race, and bearing to the left case.





20. Install the J 44757-2 (5) onto the driveshaft. Tighten until snug.
21. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), and nuts and washers (3) to the left case.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).

22. Rotate the driveshaft, multiple times in both directions to ensure the bearing rollers are seated to the bearing races.