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Transfer Case Assemble
^ Tools Required
- DT-47847 Front Output Shaft Seal Installer
- DT-47946 Bearing Installer
- J 3289-20 Holding Fixture
- J 8614-01 Flange and Pulley Holding Tool
- J 22912-01 Split Plate Bearing Puller
- J 36850 Transjel Lubricant
- J 42176 Universal Driver Handle - Non-Threaded
- J 42738 Seal Installer
- J 45380 Transfer Case Rear Bushing Remover and Installer
- J 45756 Rear Output Shaft Seal Installer
- J 45757 Mainshaft Support Bushing and Bearing Installer
- J 45759 Assembly Fixture





Notice: If removed, install the transfer case mounting studs.

1. ^ Tighten the adapter studs to 14 Nm (10 ft. lbs.).





2. Using the adapter studs, attach the J 45759 to the front transfer case. All of the assembly procedures can be performed with the case mounted to the J 45759.
3. Install the J 45759 (2) into the J 3289-20 (1) and secure with the pivot pin.





4. If the vent is removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
5. Install the vent.
^ Tighten the vent to 6 Nm (53 inch lbs.).





6. Install the ring gear in the front case half.





7. Install a NEW ring gear retaining ring.





Important: Lubricate all of the bearings and bearing journals with transfer case fluid during installation.

8. Install the input shaft bearing in the front case half.
^ Use a hammer and a brass drift only on the outer bearing race.
^ Ensure the bearing is kept square to the bore while installing.





9. Install the front output shaft front bearing in the front case half.
^ Use a hammer and a brass drift only on the outer bearing race.
^ Ensure the bearing is kept square to the bore while installing.





10. Install the front output shaft.





Important: DT-47946 is a double ended tool. In order to install the mainshaft front support bearing to the proper depth, ensure the correct end of the DT-47946 is used.

11. For the BW 4493 planetary carrier, the short reach end of the tool is used.
For the BW 4494 planetary carrier, the long reach end of the tool is used.
Using the J 42176 (1) and the DT-47946 (2), install the mainshaft front support bearing in the high/low planetary carrier assembly model 4493 (3) or 4494 (4).





12. Install the high/low planetary carrier assembly model 4494 (1) or 4493 (2).





13. Lubricate the input shaft needle thrust bearing with J 36850, or equivalent.
14. Install the input shaft thrust bearing.





15. Install new shift fork pads, if removed.
16. Install the high/low range sleeve in the high/low range fork.





17. Align the gear teeth on the high/low range shift sleeve to the high/low planetary carrier.

18. Install the high/low range shift fork and the high/low range sleeve.





19. Install the mainshaft.





Notice: In order to prevent component damage, properly remove and install the shift cam and shaft assembly. When removing or installing the shift cam and shaft assembly, keep the shaft straight and do not tilt. Tilting the shift cam and shaft assembly in the transfer case housing will break the tip on the end of the shaft.

20. Install the shift cam and shaft assembly.
1. Install the shift cam and shaft assembly straight, with the tip into the hole in the case.
2. Rotate the high/low range shift fork to position the shift fork roller in the shift cam slot.





21. Install the shift fork shaft.

Oil Pump:

22. Connect the oil pump hose to the oil pump screen.
23. Connect the oil pump hose to the oil pump.





24. Install the oil pump assembly with the hose and screen.
0. Align the square boss of the oil pump gear with the flat area on the mainshaft.
1. Install the oil pump in the slot of the front case half. Ensure the wear clip is on the oil pump.
2. Install the oil pump screen in the front case half.





25. Install the magnet.





26. Install the lower center support bearing thrust washer.





27. Install the center bearing support.





28. Install the upper center bearing support thrust washer.





29. Install the inner lockup hub.





30. Assemble the lockup mode shift collar assembly, if necessary.
0. Install the spring in the collar.
1. Install the hub, with the external tabs toward the spring.
2. Install the retainer ring in the collar.





31. Install the lockup mode shift fork to the lockup mode shift collar assembly.





32. Install the lockup mode shift collar assembly and lockup mode shift fork.
^ Slide the shift fork and collar assembly over the shift fork shaft.
^ Turn the mainshaft in order to align the slot on the inner lockup hub with the large tooth area on the hub of the lockup shift collar assembly.





Important: If using the chain and sprockets again, ensure to align the marks of the drive chain and sprockets.

33. Install the drive chain and sprockets.
^ The blue link on the chain faces up.
^ Align the drive sprocket engagement teeth with the lockup shift assembly hub teeth.





34. Install the front output sun gear.





Important: The planetary differential gears are timed to the sun gears. If the gears are not timed properly, the differential will not rotate without binding.

35. With the rear side of the planetary differential facing up, align the marks on the pinion gears. Position the alignment marks with an area on the planetary differential that can be reference for all gears.