Assembly

^ Tools Required:
- J 7079-2 Driver Handle
- J 37668 Seal Installer
- J 38212 Needle Bearing Installer
- J 38216 Seal Installer
- J 38423 Front Output Shaft Front Bearing Installer
- J 8092 Driver Handle
- During assembly of the transfer case, lube all necessary parts with Dexron III Automatic Transmission Fluid or the equivalent.





ASSEMBLE
1. Viscous clutch, drive sprocket (with the "E" facing down), drive sprocket spacer, and the sun gear shaft bearing onto the sun gear shaft.





2. Input shaft pilot bearing into the output shaft assembly using J 7079-2 and J 38212.





3. Output shaft assembly to the ring gear.





4. Gear ring snap ring to the gear ring.





5. Output shaft bearing to the front cover using J 8092 and J 38423.





6. Output shaft bearing snap ring to the front cover.





7. Output shaft rear bearing to the rear case half using J 7079-2 and J 38212.

INSTALL OR CONNECT
1. Output shaft assembly and gear ring through the rear case half.





2. Output shaft bearing snap ring to the output shaft bearing.
3. Apply an 3.175 mm (0.125 inch) bead of RTV sealer (GM P/N 12345739) or the equivalent to the rear case half extension housing sealing surface.





4. Extension housing and the extension housing bolts to the rear case half.

Tighten
- Extension housing bolts to 37 Nm (26 lb. ft.).

5. Speed sensor and speed sensor bolt into the extension housing.

Tighten
- Speed sensor bolt to 16 Nm (12 lb. ft.).








6. Output shaft oil seal to the extension housing using J 37668. Align the water drain hole in the output shaft oil seal with the drain groove in the extension housing.
7. Planet carrier assembly thrust washer to the output shaft assembly using petroleum jelly and align with the input shaft pilot bearing.





8. Planet carrier assembly into the ring gear.





9. Sun gear shaft thrust washer to the planet carrier assembly using petroleum jelly.





10. Sun gear shaft assembly into the planet carrier assembly planet gears and align the viscous clutch teeth to the ring gear spline.





11. Input shaft into the input shaft pilot bearing aligning the input shaft with the sun gear shaft thrust washer and the planet carrier assembly thrust washer.
12. Driven sprocket onto the front output shaft.
- Install the driven sprocket with the letter "E" facing down.
13. Drive chain onto the driven sprocket.





14. Drive chain over the drive sprocket and the front output shaft into the output shaft rear bearing.





15. Front output shaft spacer onto the front output shaft.
16. Magnet to the rear case half.
17. Apply an 3.175 mm (0.125 inch) bead of RTV sealer (GM P/N 12345739) or the equivalent to the rear case half front cover sealing surface.
18. Front cover and front cover bolts to the rear case half.

Tighten
- Front cover bolts to 42 Nm (30 lb. ft.).

19. Front output shaft oil seal to the front cover using J 37668.
20. Input shaft oil seal using J 38216.





21. Front output flange to the front output shaft.
22. Rubber sealing washer, steel flat washer, and a new front output flange nut.

Tighten
- Front output flange nut to 115 Nm (85 lb. ft.).