Part 1

Transfer Case Assemble

^ Tools Required
- J 3289-20 Holding Fixture
- J 8092 Universal Driver Handle
- J 36371 Output Shaft Bearing Installer
- J 36373 Input Sun Gear Ball Bearing Installer
- J 37668-A Seal Installer
- J 42738 Seal Installer
- J 45235 Rear Speed Sensor Reluctor Wheel Installer
- J 45236 Front Output Shaft Seal Installer
- J 45237 Input Gear Thrust Bearing Installer
- J 45239 Needle Bearing Installer
- J 45380 Transfer Case Rear Bushing Remover and Installer
- J 45759 Assembly Fixture





1. Important: o Because of manufacturing design changes, the transfer case was manufactured with either 1st design oil pump suction pipe components or the 2nd design oil pump suction pipe assembly. The 2nd design oil pump suction pipe assembly is a 1 piece design and is serviced as an assembly. The changes are for manufacturing purposes only and do not enhance the performance of the transfer case.
^ Install the input gear seal after the transfer case is assembled.
^ Do not cock the bearing when installing. Ensure to squarely install the bearing in the bore.

Using a suitable bearing installer, install the rear output shaft bearing. Ensure the bearing installer is used against the outer race of the bearing.





2. Using the driver of the J 36371, install the front output shaft rear bearing into the rear case half.





3. Using the J 8092 (1) and the J 45239 (2), install the control actuator lever shaft bearing until it bottoms in the bore. The seal side of the bearing faces the encoder motor.





4. Install the control actuator lever shaft in the rear case half.





5. Install a new control actuator lever shaft retaining ring.

Oil Pump Suction Pipe Assembly, 1st Design:

6. If 1st design, install the oil pump screen and oil pump hose to the oil pump suction pipe.





7. Install a new O-ring seal onto the oil pump suction pipe.
8. Lightly lubricate the O-ring seal with transfer case oil.
9. Install the oil pump suction pipe assembly in the rear case half. Ensure the oil pump suction pipe is fully seated.





10. Install the chip collector magnet in the rear case half.





11. Apply a thin layer of retaining compound GM P/N 12377901 (Canadian P/N 10953504) or equivalent to the vent, if removed.
12. Tap the vent into the case. Ensure the vent is aligned in the direction shown.





13. Important: Install the front output shaft seal after the transfer case is assembled.

Using the J 36371, install the front output shaft front bearing into the front case.





14. Using a press, install the input gear bearing into the front case.
^ Ensure the press plates fit properly on the case.
^ Use a suitable press tool that fits to the bearing outer race.





15. If removed, install the input gear thrust bearing into the input gear using the J 8092 (1) and the J 45237 (2).





16. Using a press, press the input gear assembly into the input gear bearing.
1. Support the front case half on press plates to allow the input gear to protrude.
2. Support the inner race of the input gear bearing.
3. Use a suitable press plate on the end of the input gear.
4. Press on the input gear until fully seated against the input gear bearing.





17. Install the rear output shaft thrust washer. Align the tabs with the shaft splines.





18. Install a new retaining ring, for the clutch housing, on the rear output shaft. Ensure the retaining ring is properly installed in the groove.





19. Install the drive sprocket onto the clutch housing.





20. Install a new retaining ring for the drive sprocket on the clutch housing.





21. Lightly lubricate the clutch housing inner bearing with transfer case fluid.
22. Install the clutch housing onto the rear output shaft.





23. Install the clutch hub into the clutch housing.





24. With the friction material facing down, install an outer clutch disc into the clutch housing.





25. With the friction material facing down, install an inner clutch disc into the clutch housing.
26. Continue to install the outer clutch disc and inner clutch disc, alternating until 9 of each are installed.





27. Install a new clutch hub retaining ring onto the rear output shaft.





28. Install the clutch spring.





29. Install the clutch apply plate.
^ Ensure the clutch apply plate tabs are aligned with the clutch hub.
^ Ensure the clutch spring is seated properly in the underside groove of the clutch apply plate.





30. Install the clutch pressure plate bearing. The bearing will only install in one direction. The bearing will fit flush to the inner plate when properly installed.





31. Install the clutch inner plate.





32. Important: The marks on the clutch pressure plate bearing must be aligned before installing the clutch apply plate retaining ring.

Align the markings on the clutch pressure plate bearing.





33. While pushing down on the clutch apply plate, install the clutch apply plate retaining ring.





34. Install the clutch lever to the rear case half.
^ Position the clutch lever onto the 2 pivot pins.
^ Shift the control actuator lever shaft to the neutral position.





35. Important: Ensure the flat area on the rear output shaft is aligned with the shift fork.

Install the rear output shaft assembly.





36. Using a hydraulic press and the J 36373, install a new front speed sensor reluctor wheel onto the front output shaft.





37. Install the driven sprocket onto the front output shaft.
38. Install a new driven sprocket retaining ring onto the front output shaft.





39. Important: If using the drive chain again, align the marks made during disassembly for proper wear pattern alignment.

Install the drive chain assembly.
0. Position the drive chain on the driven sprocket on the front output shaft.
1. Position the drive chain on the drive sprocket on the rear output shaft.
2. Install the front output shaft into the front output shaft rear bearing.