Stpes 49 - 105

49. Install a steel clutch pressure plate.
50. Continue to install the friction and the steel clutch plates, alternating until 10 friction plates and 9 steel plates are installed.





51. Install the clutch hub retaining ring.





Important: A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload can cause driveability concerns and failure of the transfer case.

52. Securely install the base plate (3) of the J 44295 in a vise with the machined surface of the locating tabs facing up.
53. Install the assembled rear output shaft with the clutch housing, the inner clutch plates, and the outer separator plates on the base plate (3) of the J 44295.
54. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
55. Place the gage block (2) of the J 44295 on one Of the locating tabs of the base plate (3) of the J 44295.
56. Using a feeler gage, measure between the gage block (2) and the weight (1) of the J 44295.
57. Measure with the gage block (2) and the feeler gage on the remaining two locating tabs of the base plate (3).
58. The average of the three measurements is the required shim thickness.

Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.

59. Select from the clutch plate shim package the correct shim or shims plus or minus 0.10 mm (0.004 inch). You may use a combination of two shims to obtain the correct thickness.
The shims in the clutch plate shim package are the following thickness:
^ 0.30 mm (0.12 inch)
^ 0.56 mm (0.022 inch)
^ 0.81 mm (0.032 inch)
^ 1.04 mm (0.041 inch)
^ 1.30 mm (0.051 inch)
^ 1.55 mm (0.061 inch)
^ 1.80 mm (0.071 inch)
^ 2.08 mm (0.081 inch)
60. Remove the weight (1) of the J 44295.





Important: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then reinstall the clutch plates, it could change the measurement.

61. Install the shim or shims.





62. Using a suitable press plate and a hydraulic press, press the clutch pressure plate bearing hub in the clutch pressure plate bearing. Ensure the bearing inner bearing race is supported.
63. Install the clutch pressure plate bearing and hub in the clutch pressure plate.





64. Install the clutch pressure plate spring.
65. Align the tabs on the clutch pressure plate with the grooves in the clutch hub and install the Clutch pressure plate assembly. Ensure the spring is installed in the groove of the pressure plate.





66. Install the clutch pressure plate retaining ring. Push down on the pressure plate to access the retaining ring groove.





67. Align the tab on the clutch pressure plate bearing hub with the clutch lever.
68. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
69. Install the rear output shaft assembly.





Important: Ensure to align the marks of the drive chain and sprockets if reusing the chain and sprockets.

70. Install the drive chain and sprockets.





71. Install the drive sprocket retaining ring.





72. Install the driven sprocket retaining ring.





73. Install the oil pump seal.
74. Install the rear output shaft retaining ring.





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





76. Install the oil pump assembly.





77. Install the oil pump screen.
78. Install the connector on the oil pump screen.
79. Install the oil pump suction pipe to the oil pump.
80. Connect the oil pump suction pipe to the connector.





81. Install the transfer case magnet.





82. Install the rear output shaft speed sensor reluctor wheel.





Important: Install the rear output shaft bearing with the groove for the retaining ring facing up.

83. Install the rear output shaft bearing.





84. Install the rear output shaft bearing retaining ring.
85. 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: A new oil pump wear sleeve may have a star shaped hole or a spring clip hole.

86. If necessary, install the oil pump wear sleeve.

87. Lightly stake the oil pump wear sleeve pin to hold the sleeve in place, if star shaped hole style.





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.

88. Install the locating pins in the front case, if necessary.
89. 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 half.





90. Lower the rear case half in to place.





91. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing,
92. 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.

93. Install the new case bolts, washers, and brackets.
^ Tighten the case bolts to 37 Nm (27 ft. lbs.).





94. Install the access hole plug.





95. If removed, install the transfer case mounting studs to the height of 29.5 mm - 30.5 mm (1.16 - 1.20 inch).





96. Install the rear vehicle speed sensors.
^ Tighten the speed sensor to 15 Nm (11 ft. lbs.).





97. Install the front vehicle speed sensor.
^ Tighten the speed sensor to 15 Nm (11 ft. lbs.).





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





101. Install a new rear output shaft bushing, using the J 45380.
101.1. Install the bushing or the finger section of the J 45380.
101.2. Install the finger section to the main body of the J 45380.
101.3. Position the bushing and tool to the case.
101.4. Using a hammer and the J 45380, install the bushing.





102. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
103. Using the J 37668-A, install the rear output shaft seal.





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





105. Using the J 42738, install the front input shaft seal.