Part 2 of 2

Transfer Case Assemble Con't

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.





23. Install J 8001 (3) onto the J 44757-6. Position the tip (2) of the indicator onto the end of the J 44757-2.
24. Tighten the nut (4) of the J 44757-2 to preload to the bearings and position the shaft at the bottom of travel. Use a second wrench to hold the J 44757-2 shaft. Observe the needle on the dial. When the needle movement stops, the shaft is at bottom of travel.
25. Zero the dial indicator.
26. Loosen and back-off the nut (4).
27. Tighten the nut (1) to preload the bearings and position the shaft at the top of travel. Use a second wrench to hold the J 44757-2 shaft.
28. Record the measured value on the dial indicator. Subtract the measured value from 6.0 mm (0.236 inch) in order to determine the driveshaft shim required for proper bearing installation and preload.





29. Disassemble the shaft (1), bearing (3), and J 44757-7 shim (2) from the left case.
30. Install the proper size shim (2), shaft (1), bearing (3).





31. Lightly lubricate the splines of the driveshaft with grease.
32. Use the J 5590 (1) and a hydraulic press in order to install the bearing, proper size shim, and gear (2) onto the shaft.





33. Install the left case (2) onto the J 44755 (1). Align the notched area of the tool with the flat areas of the driveshaft.





34. Install a new nut (1) onto the driveshaft.
^ Tighten the nut to 505 Nm (372 ft. lbs.).
35. Measure the rotating torque of the driveshaft. A properly assembled shaft and bearings should have a rotating torque of 1.5 Nm (13 inch lbs.).





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





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





38. Use the J 44752 (1) and a hydraulic press in order to install the inner bearing to the differential carrier.





39. Important: The J 44757-4 shim is installed to create measurable end play and assist in determining the proper size shim for bearing preload.

Install the carrier (4), J 44757-4 shim (3), and bearing (1) to the right case (2).





40. Use the J 44752 (1) and a hydraulic press in order to install the carrier, J 44757-4 shim, and bearing to the right case.





41. Install the right case (1) onto the J 44755 (2). Position the carrier onto the post of the fixture.





42. Install the J 44757-5 (5) onto the carrier. Tighten until snug.
43. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), nuts and washers (3), and nuts (6) to the right case.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
44. Rotate the differential carrier multiple times in both directions to ensure the bearing rollers are seated to the bearing races.





45. Install J 8001 (3) onto the J 44757-6. Position the tip (2) of the indicator onto the end of the J 44757-5.
46. Tighten the nut (4) of the J 44757-5 to preload to the bearings and position the differential carrier at the bottom of travel. Use a second wrench to hold the J 44757-5 shaft. Observe the needle on the dial. When the needle movement stops, the carrier is at bottom of travel.
47. Zero the dial indicator.
48. Loosen and back-off the nut (4).
49. Tighten the nut (1) to preload the bearings and position the carrier at the top of travel. Use a second wrench to hold the J 44757-5 shaft.
50. Record the measured value on the dial indicator. Subtract the measured value from 10 mm (0.394 inch) in order to determine the carrier shim required for proper bearing installation and preload.





51. Disassemble the carrier (4), bearing (1), and J 44757-4 shim (3) from the right case (2).
52. Install the proper size shim (3), carrier (4), and bearing (1) to the right case (2).





53. Use the J 44752 (1) and a hydraulic press in order to install the shaft, proper size shim, and bearing to the right case.





54. Install the nut (1) to the differential carrier.
^ Tighten the nut to 500 Nm (369 ft. lbs.).
55. Measure the rotating torque of the carrier. A properly assembled carrier and bearings should have a rotating torque of 1.5 Nm (13 inch lbs.).
56. Using a punch, stake the flange of the nut to the groove in the carrier shaft.





57. Use the J 44752 (1) in order to install the seal (2) to the right case.





58. Remove the right case (1) and carrier from the J 44755 (2).





59. Install a random size shim (3), housing (2), and bolts (1 and 4) to the left case.
^ Tighten the M8 bolts to 32 Nm (23 ft. lbs.).
^ Tighten the M10 bolts to 60 Nm (44 ft. lbs.).





60. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the shim (2).
61. Install the housing (1), selected shim (2), and bolts (3) to the housing.
^ Tighten the bolts to 32 Nm (23 ft. lbs.).





62. Install an M8 x 1.25 bolt (1) into a threaded hole in the flange.
63. Position the top of J 8001 (2) against the flat area of the bolt.





64. Install a wrench or socket onto the nut (1) of the driveshaft. Do not allow the shaft to rotate or move when measuring backlash.
65. Rotate the flange (2) left and right in order to measure the drive and drivenshafts gear backlash. Measure the backlash in multiple locations. The correct gear backlash is 0.2 - 0.3 mm (0.0078 - 0.0118 inch).





66. Select and install the correct shim (4) to obtain the proper backlash. A change in shim thickness has a one-to-one ratio and change in gear backlash.
^ A thicker shim will increase backlash.
^ A thinner shim will decrease backlash.
67. Install a new O-ring (5) during final assembly.





68. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the sealing surfaces of the right case.
69. Install the idler gear (1) to the right case.





70. Install the idler gear into the right case. The side of the gear with the long flange area (1) should be installed to the right case.





71. Rotate the J 44755 90 degrees.
72. Install the right case (2) to the left case (1).





73. Install the bolts (1) and tighten as follows:
^ Tighten the M8x40 case bolt (1) to 32 Nm (24 ft. lbs.).
^ Tighten the M10x60 case bolts (2) to 60 Nm (44 ft. lbs.)
^ Tighten the M10x50 case bolt (3) LY7 only to 60 Nm (44 ft. lbs.)
^ Tighten the M10x75 case stud bolts (4) LY7 only to 60 Nm (44 ft. lbs.)





74. Install the speed sensor (1) and O-ring.





75. Install the hose and clamp (1), vent hose (2), and bolt (3).
^ Tighten the vent hose/speed sensor bolt to 30 Nm (22 ft. lbs.).





76. Install the transmission oil drain plug (1) and gasket.
^ Tighten the drain plug to 32 Nm (24 ft. lbs.).





77. Install the gear oil drain plug (1) and gasket.
^ Tighten the drain plug to 32 Nm (24 ft. lbs.).

78. Important: The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer located behind the transmission sun gear. The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components, excluding gaskets and seals, are replaced.

Perform the transfer case selective washer measurement procedure as required. Refer to Transmission to Transfer Case End Play Check (F4WD Only). Refer to the Installation and Fluid Fill Procedure in Transfer Case and/or Seal Replacement in Transfer Case - Steyr.