Steps 31 - 74

31. Install the synchronizer retaining ring. Ensure the retaining ring is fully seated in the groove.





32. Install the two/four wheel drive mode shift fork on the synchronizer assembly.
33. Install the shift shaft in the mode shift fork.





Important: Ensure the mode shift fork is installed with the roller side down.

34. Install the clutch gear.
35. Install the shift shaft and the synchronizer assembly with the rear output shaft in the front case half and the high/low range collar.





36. Install the two/four wheel drive synchronizer gear.
^ Ensure to align the middle synchronizer tabs to the gear.
^ Ensure the gear is aligned to the synchronizer sleeve.





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

37. Install the drive chain on the front output shaft and the rear output shaft assembly.





38. Install the drive sprocket retaining ring.





39. Install the driven sprocket retaining ring.





40. Install a NEW O-ring seal for the oil pump pick up tube in the oil pump.





41. Install the oil pump on the rear output shaft.





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

42. Install the speed reluctor wheel.





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

43. Install the rear output shaft bearing.





44. Install the rear output shaft bearing retaining ring.





45. Install a new O-ring seal on the shift detent spring bolt.

Notice: Refer to Fastener Notice in Service Precautions.

46. Install the shift detent spring, the plunger, and the bolt.
^ Tighten the poppet bolt to 18 Nm (13 ft. lbs.).





47. Install the magnet.





48. Install a new oil pump O-ring for the oil pump suction pipe in the oil pump.





49. Install the oil pump screen in the front case half.
50. Install the connector on the oil pump screen
51. Install the oil pump suction pipe in the connector.
52. Install the oil pump suction pipe in the oil pump body.





53. Install the shift fork shaft detent spring on the shift shaft.
54. Install the locating pins in the front case half, if removed.





55. Install the oil pump wear retaining clip, only if worn or damaged.





Important:
^ Ensure that both the sealing surfaces on the front and rear case halves are free of dirt, oil, and cleaning solvent.
^ Ensure the locating pins are installed in the front case half.

56. Install the locating pins in the front case, if necessary.
57. Apply a 3.175 mm (1/8 inch) bead of RTV sealant GM P/N United States 12345739, GM P/N Canada 10953541 or equivalent to the front case half.





58. Align the outer retaining ring tabs for the rear output shaft bearing with the slot in the rear case half.
59. Install the rear case half to the front case half.





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





Notice: This component is made of magnesium and proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components or galvanic corrosion will occur. New nylon coated case bolts and aluminum washers must be used. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.

61. Align the brackets to the proper bolt holes.
62. Install the NEW case half bolts and the aluminum washers.
^ Tighten the case half bolts to 38 Nm (28 ft. lbs.)





63. Install a new rear output shaft bushing, using the J 45380.
63.1. Install the bushing or the finger section of the J 45380.
63.2. Install the finger section to the main body of the J 45380.
63.3. Position the bushing and tool to the case.
63.4. Using a hammer and the J 45380, install the bushing.





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

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





65. Using the J 43484 (2) and the J 8092 (1), install the front output shaft seal in the transfer case.





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





67. Install a NEW 0-ring seal on the vehicle speed sensor.

68. Lubricate the vehicle speed sensor 0-ring seal with transfer case fluid.

69. Install the speed sensor in the transfer case.

Tighten the speed sensor to 15 N.m (11 lb ft).





70. Install the actuator insulator to the transfer case.
71. Install the encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
72. Install the mounting bolts for the encoder motor.
^ Tighten the encoder motor mounting bolts, in the sequence shown, to 20 Nm (15 ft. lbs.).





73. Install the vent tube elbow, if damaged.





74. Install the access hole plug in the transfer case.