1 Thru 36

Transfer Case Assemble

^ Tools Required
- J 8092 Bearing Installer Driver Handle
- J 193831 Input Seal Installer
- J 113843 Output Shaft Extension Housing Seal Installer
- J 136371 Output Shaft Front and Rear Bearing Installer
- J 136372 Input Shaft Front Bearing Installer
- J 136373 Input Gear Bearing installer

Important: It is not recommended to replace bearings separately. Some bearings may only be replaced in a sub assembly.





1. Using the J 36372 (2) and the J 8092 (1), install the input bearing.





2. Using the J 36371, install the rear output shaft bearing.





3. Using the J 36371, install the front output shaft bearing.





4. Install the front output shaft bearing retaining ring.





5. Using the J 36373 (2) and the J 8092 (1), install the input shaft pilot bearing.





6. Using the J 33843, install the rear output shaft oil seal.





7. Install the first input gear thrust washer.





8. Install the input gear.





9. Install the second input gear thrust washer.





10. Install the input gear thrust plate.





11. Install the input gear retaining ring.





12. Using the J 33831, install the input shaft oil seal.





13. Install the drive sprocket (teeth facing away from the from the synchronizer assembly).





14. Install the synchronizer stop ring (teeth facing away from the synchronizer hub).





15. Install the synchronizer hub assembly.





16. Install the synchronizer hub retaining ring.





17. Install the planetary assembly.





18. Install the input shaft retaining ring.

Important: Make sure that all sealing surfaces are clean of solvent and dirt.

19. Apply a thin bead of silicone sealant GM P/N 12345739 or equivalent.
20. Apply threadlocker GM P/N 12345382 or equivalent to the bolts.





21. Install the front case bearing retainer.
^ Tighten the bearing retainer bolts to 19 Nm (14 ft. lbs.).





22. Install the sector shaft assembly.





23. Install the sector shaft O-ring.
24. Install the plastic sleeve.
25. Install the sector shaft retaining ring.





26. Install the poppet assembly.
27. Install the poppet nut.
^ Tighten the poppet nut to 15 Nm (11 ft. lbs.).





Important: Make sure that the pads on the range shift fork have been replaced before installing the range shift sleeve.

28. Install the range shift sleeve.





Important: Make sure that the range shift fork assembly is properly seated on the sector assembly.

29. Install the range shift fork assembly.





Important: Make sure that the pads on the mode fork have been replaced before installing the mode fork.

30. Install the mode fork on the mainshaft.





31. Install the mainshaft assembly.





32. Install the mode fork retaining spring and cover.





Important: Make sure that the reference marks on the drive sprockets and the drive chain are aligned.

33. Install the drive chain assembly.





34. Install the O-ring in the oil pump assembly.





35. Install the oil pump assembly.
36. Install the oil pump pick up assembly.