Steps 40 - 80

40. Install the inner clutch drum retaining ring.





41. Install the clutch drum flange.
- Ensure the clutch drum flange is installed with the ridge side of the flange facing down.
- Align the teeth on the clutch drum flange with the slots in the inner clutch drum.





42. Install a inner clutch plate over the clutch drum flange.





43. Install a outer separator plate over the inner clutch plate.





44. Install a inner clutch plate over the outer separator plate.





45. Install a outer separator plate over the inner clutch plate.
- Continue installing inner clutch plates and outer separator plates until ten inner clutch plates and nine outer separator plates are installed into the clutch drum.
- After installation of the ten inner clutch plates and the nine outer separator plates, an inner clutch plate should be on top of the plate stack.
- The tabs on all of the separator plates should all be aligned.

46. Shim the clutch pack. Refer to Cleaning and Inspection (Clutch Pack Shim Procedure).





47. Using a press, install the inner bearing support into the thrust bearing.
Install the thrust bearing and inner bearing support plate into the outer bearing support plate.





48. Install the thrust bearing, inner and outer bearing support plates onto the main shaft and into the inner clutch drum.
Ensure all of the tabs are aligned.





49. Install the clutch retaining ring onto the mainshaft.





50. Install the mainshaft in to the front case half.
- Align the tabs on the inner bearing support with the clutch lever inserts.
- The clutch drum on the mainshaft should align with the front case half.
- During installation of the mainshaft, align the teeth on the mainshaft with the teeth inside planetary gear and range shift sleeve.





51. Position the drive sprocket and driven sprocket into the chain.





52. Install the chain with the drive and driven sprockets onto the mainshaft and front output shaft.





53. Install the drive and driven sprocket retaining rings onto the mainshaft and front output shaft.





54. Install the gerotor pump retaining ring onto the mainshaft. Ensure the retaining ring is not positioned over the oil hole on the mainshaft.





55. Install the oil pump o-ring into the oil pump inlet hole.





56. Install the oil pump onto the mainshaft.
- Ensure the oil pump seats on the mainshaft flange.
- Ensure the oil pump inlet hole is pointing toward the front output shaft.





57. Install the oil pump pickup tube into the oil pump inlet hole and o-ring.
58. Position the oil pickup tube under the chain.
59. Install the oil screen into the front case half.
60. Secure the screen to the pickup tube with the nylon tube.





61. Install the magnet into the front case half.





62. Install the tone wheel onto the main shaft.
63. Install the rear output bearing onto the main shaft.
64. Install the rear output bearing retaining ring onto the mainshaft.





65. Using a thin coat of clear RTV, install the oil pump retainer tab into the rear case half.





66. Install two case half alignment dowels into the front case half.





67. Install the rear case half onto the front case half.
- Apply RTV sealant to the mating surfaces of the front and rear case halves.
- During the assembly of the front and rear case halves, the rear output bearing retaining ring must be spread open to allow for the case halves to join.
- Do not use an impact gun with case half bolts to drive the case halves together.
- Use a rubber mallet to position the case halves together while spreading the rear output bearing retaining ring.





68. Install the case half bolts, studs, and washers into the front and rear case halves.
- Tighten the case half bolts and studs to 37 Nm (27 ft. lbs.).
- Ensure the threads on the case half bolts and studs are clean and free of all existing pre-applied thread fastener compounds, corrosion, and debris.
- Apply Loctite(R) PST 565, Loctite(R) PST 242, or the equivalent to the threads of the case half bolts and studs.
- Ensure the bolts and studs are installed and tighten within ten minutes after the new thread fastener is applied.
- Ensure all case half bolts, studs, washers, and brackets are installed in the same location from where they were removed.
- The transfer case being repaired may or may not have aluminum washers with the case have bolts and studs. Aluminum washers were added during early to mid-year production.

IMPORTANT:
- Do not use steel bolts, studs, or washers to secure the case halves together.
- Any case half bolts, studs, or washers that are worn or broken must be replaced with the correct GM replacement bolts, studs, or washers. A steel bolt, stud, or washer will cause accelerated corrosion that will destroy the integrity of the magnesium case, severe oil leakage, and transfer case malfunction.





69. Install the case half bolts, studs, and washers into the front and rear case halves.
View of the opposite side of the transfer case.
- Tighten the case half bolts and studs to 37 Nm (37 ft. lbs.).
- Ensure the threads on the case half bolts and studs are clean and free of all existing pre-applied thread fastener compounds, corrosion, and debris.
- Apply Loctite(R) PST 565, Loctite(R) PST 242, or the equivalent to the threads of the case half bolts and studs.
- Ensure the bolts and studs are installed and tighten within ten minutes after the new thread fastener is applied.





70. install the two studs securing the transfer case shield mounting bracket to the transfer case.
- Tighten the two studs to 37 Nm (27 ft. lbs.).
- Ensure the threads on the studs are clean and free of all existing pre-applied thread fastener compounds, corrosion, and debris.
- Apply Loctite(R) PST 565, Loctite(R) PST 242, or the equivalent to the threads of the studs.
- Ensure studs are installed and tighten within ten minutes after the new thread fastener is applied.





71. Install the six input shaft studs into the front case half.
- Ensure the threads on the studs are clean and free of all corrosion and debris.
- Tighten the six studs to 37 Nm (27 ft. lbs.).





72. Install the front speed sensor into the front case half.
- Tighten the front speed sensor to 31 Nm (23 ft. lbs.).





73. Using the retaining ring separating hole, ensure the rear output bearing retaining ring is properly seated in the bearing groove.
74. Install the rubber plug into the rear case half.





75. Install the two rear speed sensors into the rear case.
- Tighten the rear speed sensors to 31 Nm (23 ft. lbs.).





76. Install the O-ring and transfer case vent tube into the transfer case.
Vent tube installation is only necessary if the vent tube is being replaced.





77. Install the motor/encoder gasket and motor/encoder to the transfer case with three bolts.
- Tighten the bolts to 37 Nm (27 ft. lbs.).
- The motor/encoder, sector shaft, and motor/encoder, transfer case bolt mounting holes should all be aligned during installation.
- Ensure the gasket remains aligned with the bolt mounting holes during installation.
78. Remove the fill plug.
79. With the transfer case level, fill the transfer case up to the fill plug with Dexron(R) III, GM P/N 12346143
80. Install the fill plug.
- Tighten the oil fill plug to 20 Nm (15 ft. lbs.).