Steps 31-60

Transfer Case Assemble (Continued)





Important: When performing the following service procedure, make sure that marks that were used to mark the position of the chain to the relationship of the chain to the sprockets.

31. Install the drive chain assembly.





32. Install the driven sprocket retaining ring.





33. Install the drive sprocket retaining ring.





34. Install the seal for the oil pump pick up tube in the oil pump.





Important: The super duty version of the NVG 261 transfer case does not use a oil pump seal.

35. Install the oil pump assembly seal.





36. Install the oil pump assembly.





Important: For the super heavy duty version of the NVG 261 the tone wheel must be aligned with the groove toward the oil pump assembly.

37. Install the tone wheel.





Important: The super duty version of the NVG 261 transfer case does not use a retaining ring for the tone wheel.

38. Install the tone wheel retaining ring.





Important: When installing the rear output shaft bearing on the mainshaft, make sure that the groove on the rear output shaft bearing is facing up.

39. Install the rear output shaft bearing.





40. Install the rear output shaft retaining ring.





41. Install the oil pump screen.
42. Install the connector on the oil pump screen
43. Install the oil pump pick up tube in the connector.
44. Install the oil pump pick up tube in the oil pump body.





45. Install the magnet.





46. Install the shift rail spring.
47. Install the transfer case locating dowels (if needed).





48. Install the oil pump wear sleeve (only if the sleeve is worn or damaged).





Important: Make sure that both sealing surfaces for the front and rear cases are clean and free of oil or cleaning solvent.

49. Apply an 1/8 in bead of RTV sealant GM P/N 12345739 or equivalent to the front case half.





Important: Before install the rear case half, make sure that the retaining ring for the rear output shaft bearing is aligned with the access slot.

50. Install the rear case half on the rear output shaft bearing.
51. Using a pair of snap ring pliers, open the outer retaining ring for the rear output shaft bearing.





52. Install the rear case half to the front case half.





Important: When installing the transfer case bolts, make sure that they are installed in the proper location.

53. Install the transfer case retaining bolts.
^ Tighten the transfer case retaining bolts to 38 Nm (28 ft. lbs.)





Important: Make sure that the drain hole in the seal boot is pointing down.

54. Using the J 37668-A, install the rear output shaft seal.





55. Using the (2) J 43484 and the (1) J 8092, install the front output shaft bearing seal.





56. Using the J 42738, install the input shaft seal.





57. Install the vent tube elbow (if damaged).





58. Install the speed sensor.
^ Tighten the speed sensor to 13 Nm (18 ft. lbs.)





59. Install the gear indicator switch.
^ Tighten the gear indicator switch to 27 Nm (20 ft. lbs.)





60. Install the rubber plug.