36 -74
Transfer Case Assemble Con't36. Install the planetary differential assembly.
^ Do not rotate the planetary differential pinion gears when installing.
^ Ensure the alignment marks are in position.
^ The single row pinion gears face rearward, or up. The double row pinion gears face forward, or down.
37. Lubricate the rear output shaft thrust washer with J 36850 or equivalent.
38. Install the rear output shaft thrust washer.
39. Install the rear output sun gear.
^ The shoulder side of the gear faces up.
^ Do not rotate the differential pinion gears.
40. Temporarily install the rear output shaft to the planetary differential and the rear output sun gear.
41. Rotate the rear output shaft 3 or 4 revolutions to rotate the planetary differential pinion gears. If properly aligned, the pinion gears will rotate freely and there will be no binding.
42. Remove the rear output shaft without disturbing the rear sun gear.
43. Install the shift fork shaft spring.
44. Install the front output shaft rear bearing in the rear 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.
45. Install the shift shaft seal. The seal will install using hand pressure. The spring side, or opened side, of the seal faces outward.
46. Using a hydraulic press and the J 22912-01, install the rear output shaft bearing.
^ The retaining ring groove on the bearing goes toward the input end, or forward.
^ Use a suitable press plate on the end of the rear output shaft.
^ Ensure the bearing is supported on the inner race.
47. Install a NEW rear output shaft bearing retaining ring.
48. Using a hydraulic press, install a NEW speed sensor tone wheel.
49. Using the J 42176 (1) and J 45757 (2), install the mainshaft rear support bushing in the rear output shaft.
50. Install the rear output shaft in the rear case half.
0. Spread the rear output shaft bearing outer retaining ring.
1. Install the rear output shaft bearing outer retaining ring until it is seated in the bearing groove.
Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.
Important:
^ Ensure that both the sealing surfaces on the front and rear case halves are free of dirt, oil, and cleaning solvent.
^ Ensure the locating pins are installed in the case halves.
51. Install the locating pins in the front case and rear case half, if necessary.
52. Apply a 3.175 mm (1/8 inch) bead of room temperature vulcanizing (RTV) sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.
53. Lower the rear case half into place. The rear output shaft may require rotating to align the teeth with the planetary differential.
Notice: This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. New nylon coated case bolts and aluminum washers must be used. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.
54. Inspect the case bolts nylon coating for cuts or tears.
55. Replace the case bolts if there is any damage to the nylon coating.
Important: The case bolts are self-tapping. They must be hand started. Do not use power assisted tools to install the bolts.
56. Install the case bolts with washers, and the brackets.
^ Tighten the case bolts to 25 Nm (18 ft. lbs.).
57. Using the J 45380, install the output shaft bushing, if removed or new.
58. Using the J 45756, install the rear output shaft seal.
59. Install the vehicle speed sensor with a new O-ring seal.
^ Tighten the speed sensor to 17 Nm (13 ft. lbs.).
60. Apply a 3.175 mm (1/8 inch) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541), or equivalent, to the sealing surface of the encoder motor assembly.
61. Install the encoder motor assembly (3). Rotate the shift detent lever to align to the encoder motor.
62. Loosely install the encoder motor mounting bolts (1).
63. Loosely install the encoder motor bracket bolt (2).
^ Tighten the encoder motor mounting bolts to 10 Nm (89 inch lbs.).
^ Tighten the encoder motor bracket bolt to 10 Nm (89 inch lbs.).
64. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
65. Install the drain plug and the fill plug.
^ Tighten the drain plug and fill plug to 16 Nm (12 ft. lbs.).
66. Using the DT-47847, install the front output shaft seal.
67. Install the front output shaft flange (4).
Important: Ensure the seal is fully seated before installing the washer and nut.
68. Install the front output shaft flange seal (3).
69. Install the front output shaft flange washer (2).
70. Install a NEW front output shaft flange nut (1).
71. Install the J 8614-01 to the front output shaft flange.
72. Hold the J 8614-01 and tighten the front output shaft flange nut.
^ Tighten the front output shaft flange nut to 319 Nm (235 ft. lbs.).
73. Using the J 42738, install the input shaft seal.
74. Remove the transfer case from the J 45759.