Steps 69 - 101
Transfer Case Assemble Con't69. Install the rear output shaft retaining ring.
70. Install a new oil pump O-ring for the oil pump suction pipe in the oil pump.
71. Install the oil pump assembly.
72. Install the oil pump screen.
73. Install the connector on the oil pump screen.
74. Install the oil pump suction pipe to the oil pump.
75. Connect the oil pump suction pipe to the connector.
76. Instal the transfer case magnet.
77. Install the speed sensor reluctor wheel retaining ring.
Important: Install the rear output shaft bearing with the groove for the retaining ring facing up.
78. Install the rear output shaft bearing.
79. Install the rear output shaft bearing retaining ring.
80. Align the outside retaining ring for the rear output shaft bearing so that it is easily accessed through the opening in the rear case half.
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.
81. Install the locating pins in the front case, if necessary.
82. 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 mating surfaces of the front case halve.
83. Lower the rear case half in to place.
84. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing.
85. Push down on the rear case half until the retaining ring is properly seated on 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.
86. Install the new case bolts, washers, and brackets.
^ Tighten the case bolts to 37 Nm (27 ft. lbs.).
87. Install the access hole plug.
88. If removed, install the transfer case mounting studs to the height of 29.5 - 30.5 mm (1.16 - 1.20 inch).
89. Install the rear vehicle speed sensors.
^ Tighten the speed sensor to 15 Nm (11 ft. lbs.).
90. Install the front vehicle speed sensor.
^ Tighten the speed sensor to 15 Nm (11 ft. lbs.).
91. Install the actuator insulator to the transfer case.
92. Install the encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
93. Install the mounting bolts for the encoder motor.
^ Tighten the encoder motor mounting bolts, in the sequence shown, to 20 Nm (115 ft. lbs.).
94. Install a new rear output shaft bushing, using the J 45380.
94.1. Install the bushing or the finger section of the J 45380.
94.2. Install the finger section to the main body of the J 45380.
94.3. Position the bushing and tool to the case.
94.4. Using a hammer and the J 45380, install the bushing.
95. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
96. Using the J 37668-A, install the rear output shaft seal.
97. Install the J 44636-2 on the transfer case front output shaft.
98. Install the transfer case front output shaft seal on the J 44636-2.
99. Using the J 44636- 1, install the transfer case front output shaft seal.
100. Install the dust seal.
101. Using the J 42738, install the front input shaft seal.