Part 1 of 2

Transfer Case Assemble

^ Tools Required
- J 5590 Crankshaft Sprocket Installer
- J 8001 Dial Indicator Set
- J 36797-A Seal Installer
- J 44752 Bearing, Race, and Seal Installer
- J 44753 Bearing and Seal Installer
- J 44755 Holding Fixture
- J 44757 Shim Selection Kit
- J 44907 Bearing Installer
- J 44908 Bearing Race Installer

Important:
^ The transfer case is assembled for proper gear tooth clearances, backlash, and bearing preloads with selective shims.
^ Do not assemble the internal components dry. Lightly lubricate the bearing races, bearings, gears, and oil seals with the proper lubricant. Components in the transaxle portion of the transfer case should be lubricated with DEXRON III GM P/N 12378470 (Canadian P/N 10952622) or equivalent. Components in the hypoid gear portion of the transfer case should be lubricated with GM P/N 12378514 (Canadian P/N 88901045).

Differential Carrier Assembly

Differential Carrier Assembly:

1. Install the needle bearings (4 and 6) and washer (5) to the gear (3), if required.
2. Install the pin (9), gear (3), and washers (1, 2, 7, and 8) to the differential carrier, if required.
3. Install the ring (10) to the carrier, if required.





4. Install the side gears (2), pinion gears (3), and washers (1 and 4) to the carrier, if required.





5. Install the shaft (1) and roll pin (2) to the carrier, if required.





6. Important: A comma is to be considered a decimal point.

Determine if the drivenshaft has a plus, minus, or zero value (1) etched onto the end of the gear. If the drivenshaft has a plus, minus, or zero value etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure A.





7. Determine if the drivenshaft has a 4 digit measured value (1) etched onto the end of the gear. If the drivenshaft has a four-digit number etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure B.

Extension Housing Assembly and Shim Selection - Procedure A





1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.





2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.





3. Measure the distance between the flange on the drivenshaft and the end of the pinion. Record the value as dimension B.





4. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft.





5. Install the drivenshaft (3) and NEW spacer (1) into the extension housing (2).





6. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.





7. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).





8. Lightly lubricate the splines of the drivenshaft with grease.
9. Install the flange (1) onto the shaft using a hydraulic press.





10. Notice: Refer to Fastener Notice in Service Precautions.

Install the extension housing assembly (3) and bolts (1) to the J 44755 (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





11. Install a new nut (1) onto the shaft.
^ Tighten the nut, with new bearings to 250 Nm (185 ft. lbs.).
^ Tighten the nut, with used bearings to 200 Nm (148 ft. lbs.).
12. Remove the extension housing assembly and bolts from the J 44755.





13. Important: Loosening the pinion nut to achieve proper rotating torque requires replacement with a new spacer.

Measure in both directions, the rotating torque of the drivenshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 Nm (13 inch lbs.). When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.





14. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.





15. Install the J 44757-3 (2) into the bore of the housing (1).





16. Install J 44757-9 (3) and bolts (2) to the housing (1).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 inch). Record the value as dimension D.





18. Determine if the drivenshaft has a plus, minus, or zero value etched onto the end of the gear. Note that the handwritten 1 (1) and 7 (2) are similar. The 7 (2) will have a line drawn through the number. A comma is to be considered a decimal point.
19. Calculate the extension housing shim thickness. Refer to the Extension Housing Shim Calculation Table - Procedure A.

Extension Housing Assembly and Shim Selection - Procedure B





1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.





2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.





3. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft.





4. Install the drivenshaft (3) and NEW spacer (1) into the extension housing (2).





5. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.





6. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).





7. Lightly lubricate the splines of the drivenshaft with grease.
8. Install the flange (1) onto the shaft using a hydraulic press.





9. Notice: Refer to Fastener Notice in Service Precautions.

Install the extension housing assembly (3) and bolts (1) to the J 44755 (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





10. Install a new nut (1) onto the shaft.
^ Tighten the nut, with new bearings to 250 Nm (185 ft. lbs.).
^ Tighten the nut, with used bearings to 200 Nm (148 ft. lbs.).
11. Remove the extension housing assembly and bolts from the J 44755.





12. Measure in both directions, the rotating torque of the drivenshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 Nm (13 inch lbs.). When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.





13. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.





14. Determine the 4 digit value (1) on the end of the drivenshaft gear.A comma is to be considered a decimal point. Record the value as dimension E.





15. Install the J 44757-3 (2) into the bore of the housing (1).





16. Install J 44757-9 (3) and bolts (2) to the housing (1).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 inch). Record the value as dimension D.
18. Calculate the extension housing shim thickness. Refer to Extension Housing Shim Calculation Table - Procedure B.