Internal Components

- Tools Required:
- J 8092 Driver Handle
- J 33833 Bearing Installer
- J 36372 Bearing Installer
- J 33843 Seal Installer
- J 33831 Seal Installer
- J 33832 Bearing Installer

ASSEMBLE





1. Synchronizer hub to the synchronizer sleeve along with the three struts.
- Align the scribe marks.
2. Spring retainers to the synchronizer hub.
3. Main drive synchronizer stop ring to the synchronizer sleeve and the synchronizer hub.





4. Drive sprocket to mainshaft.
5. Synchronizer assembly to mainshaft.





6. Synchronizer to the mainshaft snap ring.

INSTALL OR CONNECT





1. Planetary input gear assembly through the input bearing into the annulus using a soft faced hammer.





2. Input gear snap ring.
3. Input bearing retainer and input bearing retainer bolts to front case half.
- Apply RTV GM P/N 12345739 or equivalent on bearing retainer mating surfaces.
- Apply threadlocker GM P/N i2345382 or equivalent to bearing retainer bolts.
- Tighten input bearing retainer bolts to 19 Nm (14 ft. lbs.).
4. Shift lever O-ring, plastic washer, into front case half.





5. Selector with shaft into the front case half, shift lever, washer, and nut to the front case half.
- Tighten shift select lever nut to 27 Nm (20 ft. lbs.).





6. Range shift hub and range shift fork into the front case half.
- It is necessary to rotate the selector to align the range shift fork.





7. Chain over main shaft onto drive gear.
- Install mainshaft assembly, chain and front output shaft into case as an assembly.
8. Mainshaft assembly, mode shift fork, and rail through range shift fork into front case half.
9. Front output shaft into chain and into front case half.





10. Fork shift spring onto the mode shift rail.





11. Oil pickup tube, oil tube connector, and pump pickup screen into the rear case half.
12. Oil tube O-ring onto the oil pump pickup tube.

Important: Do not damage the O-ring during assembly as this could result in pump failure.





13. Oil pump to the oil pump pickup tube.
- Apply RTV sealer GM P/N 12345739 or equivalent to the case mating surfaces.
14. Rear case over mainshaft and onto the front case half.
- Be careful not to damage the oil pump when installing the case halves together.
15. Case bolts into case halves.
- Apply threadlocker GM P/N 12345382 or equivalent to the case bolts.
- The two longer case bolts and washers into the doweled case holes, or from their original holes on transfer cases with attaching brackets.
- Tighten case half bolts to 31 Nm (23 ft. lbs.).





16. Snap ring to the mainshaft.





17. Vehicle speed sensor rotor onto mainshaft.





18. Vehicle speed sensor rotor snap ring.
19. Rear retainer housing and rear retainer housing bolts to the rear case half.
- Apply threadlocker GM P/N 12345382 or equivalent to the rear retainer housing bolt threads.
- Tighten rear retainer housing bolts to 31 Nm (23 ft. lbs.).





20. Output bearing snap ring to the mainshaft.





21. Rear extension housing and extension housing bolts to the rear retainer housing.
- Apply RTV sealer GM P/N 12345739 to the extension housing mating surfaces.
- Apply threadlocker GM P/N 12345382 or equivalent to the extension housing bolts.
- Tighten extension housing bolts to 31 Nm (23 ft. lbs.).