Steps 45 - 90

Transfer Case Assemble Con't





45. Install the clutch lever to the rear case half.
^ Install the clutch lever over the shift fork shaft.
^ Position the clutch lever on to the 2 pivot pins.
^ Shift the control actuator lever shaft to the neutral position.





Important: Ensure the flat area on the rear output shaft is aligned with the shift fork.

46. Install the rear output shaft assembly.





47. Install the bottom retaining ring on to the shift fork shaft.





48. Install the bottom spring on to the shift fork shaft.
49. Install the range sleeve on the input gear while installing the shift fork on the shift fork shaft.





50. Install the top shift fork spring.
51. Install the top retaining ring for the shift fork. Ensure the retaining ring is properly installed in the groove.





52. Using a hydraulic press and the J 36373, install a new front speed sensor reluctor wheel on to the front output shaft.





53. Install the driven sprocket on to the front output shaft.
54. Install a new driven sprocket retaining ring on to the front output shaft.





Important: If reusing the drive chain, align the marks made during disassembly for proper wear patterns realignment.

55. Install the drive chain assembly.
55.1. Position the drive chain on the driven sprocket on the front output shaft.
55.2. Position the drive chain on the drive sprocket on the rear output shaft.
55.3. Install the front output shaft into the front output shaft rear bearing.





56. Apply a 3 mm (1/8 inch) bead of sealant GM P/N United States 12345739, GM P/N Canada 10953541, or equivalent, on to the rear case half.





57. Inspect to ensure the location pins are installed in the front case half.
58. Install any missing location pins in the front case half.
59. Install the front case half to the rear case half.
^ Rotating the output shaft will align the splines with the input gear.
^ The case halves should come together without any resistance.
^ The rear case half should align on the front case half location pins.





Notice: Refer to Fastener Notice in Service Precautions.

60. Install the front case half to rear case half bolts.
^ Tighten the case half bolts to 22 Nm (16 ft. lbs.).





61. Install the oil pump driven gear, the outer rotor.
62. Install the oil pump drive gear, the inner rotor. The flat on the inner rotor aligns to the flat area on the rear output shaft.





Important: DO NOT use sealer on the oil pump cover.

63. Install the oil pump cover.
64. Install the oil pump cover mounting bolts.
^ Tighten the oil pump cover mounting bolts to 14 Nm (10 ft. lbs.).





65. Position the NEW speed sensor reluctor wheel on to the rear output shaft.





Important: Use the J 45235 to install the rear speed sensor reluctor wheel to the proper specifications.

66. Using the J 45235 on the rear output shaft, install the rear speed sensor reluctor wheel.





67. Inspect to ensure the rear extension location pins are installed in the rear case half.
68. Install any missing location pins in the rear case half.
69. Apply a 3 mm (1/8 inch) bead of sealant GM P/N United States 12345739, GM P/N Canada 10953541, or equivalent, on to the rear extension.
70. Install the rear extension to the rear case half.
Align on the location pins.
71. Install the rear extension bolts.
^ Tighten the rear extension bolts to 22 Nm (16 ft. lbs.).





Important: The shift control detent must be in the neutral position when installing the motor/encoder.

72. Shift the shift control detent into the neutral position.

Important: A new motor/encoder will not have location pins.

73. Inspect to ensure the location pins are installed in the motor/encoder.
74. Install any missing location pins in the motor/encoder.
75. Install the motor/encoder assembly.





76. Install the motor/encoder mounting bolts.
^ Tighten the motor/encoder mounting bolts to 16 Nm (12 ft. lbs.).
77. Install the motor/encoder wiring harness bracket and case half bolt.
^ Tighten the case half bolt to 22 Nm (16 ft. lbs.).





78. Install the front Vehicle Speed Sensor (VSS).
^ Tighten the front VSS to 17 Nm (13 ft. lbs.).





79. Install the right rear VSS.
^ Tighten the right rear VSS to 17 Nm (13 ft. lbs.).
80. Install the left rear VSS.
^ Tighten the left rear VSS to 17 Nm (13 ft. lbs.).





81. Install the J 45236-2 on to the front output shaft.





82. Install the seal on to the J 45236-2 (1).
83. Using the J 45326-1 (2), install the front output shaft seal.





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





85. Using the J 45380, install a new rear output shaft bushing.

85.1. Install the bushing on the finger section of the J 45380.

85.2. Install the finger section to the main body of the J 45380.

85.3. Position the bushing and tool to the case.

85.4. Using a hammer and the J 45380, install the bushing.





86. Using the J 37668-A, install the rear output shaft seal.
86.1. Align the notch on the J 37668-A with the tab on the seal.
86.2. Install the seal with the tab at the top and the weep hole at the bottom.





87. Apply pipe sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the fill plug threads.
88. Install the fill plug.
^ Tighten the fill plug to 27 Nm (20 ft. lbs.).





89. Apply pipe sealant GM P/N United States 12346004, GM P/N Canada 10953480, or equivalent, to the drain plug threads.
90. Install the drain plug.
^ Tighten the drain plug to 27 Nm (20 ft. lbs.).