3. Transfer Case Assemble

Transfer Case Assemble

^ Tools Required
- J 8092 Universal Handle
- J 37668-A Seal Installer
- J 42738 Seal Installer
- J 43484 Seal Installer

Important: The following service procedure will cover light duty, heavy duty, and super duty version of these transfer cases. When installing the new retaining rings in any of the following service procedures, ensure that the retaining rings are properly seated before proceeding to the next service procedure.





1. Install the mounting studs to 1.16 inch to 1.20 inch in height (if damaged only).





2. Install the sector shaft assembly.





3. Install the sector shaft retaining ring.





Notice: Refer to Fastener Notice in Service Precautions.

4. Install the poppet assembly.
^ Tighten the poppet bolt 18 Nm (13 ft. lbs.)





Important: When installing the front input shaft bearing, ensure that the groove in the input shaft bearing is facing up.

5. Install the input shaft bearing.
6. Install the input shaft bearing retaining ring.





7. Install the front output shaft bearing.





8. Install the front output shaft bearing retaining ring.





9. Install the front output shaft assembly.





10. Install the front output shaft retaining ring.





11. Install the input shaft thrust washer.





12. Install the front input shaft assembly.





13. Install the input shaft thrust washer.





Important: When installing the thrust plate, make sure that the letter "E" that is stamped on the thrust plate is facing up.

14. Install the input shaft thrust plate.





15. Install the input shaft retaining ring.





16. Install the planetary gear assembly.





17. Install the input shaft retaining ring.





18. Assemble the range fork assembly.
19. Install the range fork on the range sleeve.

Important: The sector shaft must be in the 4 LO position. Rotate the shift shaft fully clockwise.

20. Install the range fork and sleeve.





21. Install the sprocket hub
22. Install the retaining ring.





Important: The synchronizer ring should be installed on the synchronizer.

23. Install the synchronizer ring.
24. Install the synchronizer hub.





25. Install the synchronizer assembly retaining ring.





26. Install the shift mode fork on the synchronizer assembly.
27. Install the shift rail in the shift mode fork.





Important: Ensure that the clutch gear pointing downward is facing the synchronizer. Make sure that the shift mode fork is installed with the pin side down.

28. Install the clutch gear.
29. Install the shift rail and the synchronizer assembly on the mainshaft in the front case half.





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.

30. Install the drive chain assembly on the front input and output shaft assembly.





31. Install the drive sprocket retaining ring.





32. Install the driven sprocket retaining ring.





Important: The super duty version of the NVG 263 transfer case does not use a oil pump seal.

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





34. Install the oil pump assembly on the mainshaft.





Important: Install the tone wheel with the step toward the oil pump assembly.

35. Install the tone wheel.





Important: The super duty version of the NVG 263 transfer case does not use a tone wheel retaining ring.

36. 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.

37. Install the rear output shaft bearing on the mainshaft.





38. Install the rear output shaft bearing retaining ring.





39. Install the magnet.





40. Install the oil pump screen in the front case half.
41. Install the connector on the oil pump screen
42. Install the oil pump pick up tube in the connector.
43. Install the oil pump pick up tube in the oil pump body.





44. Install the shift rail spring on the shift rail.





45. Install the locating dowel in the front case half if damaged.
46. Install the oil pump wear retaining clip (only if worn or damaged).





Important: Make sure that both sealing surfaces on the front and rear case halves are free of any dirt, oil or cleaning solvent.

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





48. Align outer retaining ring for the rear output shaft bearing so that it is aligned with the slot in the rear case half.
49. Install the rear case half to the front case half.





50. Using a pair of snap ring pliers, open the outer retaining ring for the rear output shaft bearing.





51. Install the retaining bolts from the rear case half to the front case half.
^ Tighten the retaining bolts to 38 Nm (28 ft. lbs.)





Important: When installing the rear output shaft seal, make sure that the drain hole is pointed down.

52. Using the J 37668-A, install the rear output shaft seal to the transfer case.





53. Using the J 43484 and the J 8092 install the front output shaft seal in the transfer case.





54. Using the J 42738, install the input shaft seal to the transfer case.





55. Install the speed sensor in the transfer case.
^ Tighten the speed sensor to 18 Nm (13 ft. lbs.)





Important: Ensure that the sector shaft is in the neutral position (same position when the motor was removed or in 2 HI if a new encoder/motor) before installing the encoder/motor.

56. Install the motor/encoder gasket to the transfer case.
57. Install the motor/encoder to the transfer case.
58. Install the mounting bolts for the motor/encoder.
^ Tighten the mounting bolts to 24 Nm (18 ft. lbs.)





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





60. Install the rubber plug in the transfer case.