Transfer Case Assemble
TRANSFER CASE ASSEMBLE^ TOOLS REQUIRED
- J44871 Output Shaft Seal Installer
- J44872 Pinion Shaft Seal Installer
- J44873 Shoulder Bolts
- J44874 Left Bearing Race Installer
- J44875 Right Bearing Race Installer
- J44884 Inner and Outer Bearing Race Installer
- J4972-4 Output Shaft Needle Bearing Installer
IMPORTANT: Heat housing to 121°C (250°F).
1. Using Inner and Outer Bearing Race Installer J44884, install bearing races into housing (1 and 2).
2. Tighten bolt on the Inner and Outer Bearing Race Installer J44884 until races are seated into housing.
3. Install shim (2) and bearing (1) onto pinion shaft (3).
4. Place shim on the pinion shaft.
5. Install bearing.
6. Install NEW collapsible spacer (2) onto pinion shaft (3).
7. Install pinion shaft (3) into housing.
8. Install bearing (1) onto pinion shaft.
9. Install slinger washer (2) and the new pinion seal (1) to the housing.
10. Install new pinion seal using Pinion Shaft Seal Installer J44872.
IMPORTANT: Use a NEW pinion nut.
11. Using a NEW pinion nut (1), install a pinion flange (2) to the pinion shaft.
12. Install Shoulder Bolts J44873 and bolts supplied in order to hold the pinion flange while tightening the nut.
13. Tighten the pinion flange nut until it is snug.
14. Tighten the nut slowly in order to crush the collapsible spacer.
Torque:
Pinion Flange Nut: 1.5 Nm (14 inch lbs.)
15. Using Output Shaft Needle Bearing Installer J4972-4 and a driver, install the axle shaft bearing (2) to the carrier (1), until the bearing seats.
16. Install ring gear (1) to carrier (2).
IMPORTANT: DO NOT reuse ring gear bolts. Install NEW bolts during assembly.
17. Tighten the ring bolts (1) in a crossing pattern, alternating from side-to-side.
Torque:
Ring Gear Bolts: 65 Nm (48 ft. lbs.)
18. Position carrier into a press.
19. Install left side carrier bearing.
20. Position carrier into a press.
21. Install right side carrier bearing.
22. Install shim (1), bearing cup (2) and vent baffle into the housing.
23. Install cup and shine using Left Bearing Race Installer J44874.
NOTICE: Do not install the seal from inside the housing. The outside diameter of the bearing cup may cause seal damage.
24. Install oil seal (1) to housing using Output Shaft Seal Installer J44871.
NOTICE: The bearing cup must be removed in order to install the seal. If the bearing cup is not removed first, seal damage may occur.
25. Install inner oil seal into cover using Output Shaft Seal Installer J44871.
26. Install shim (2) and bearing cup (3) into side cover (1).
NOTICE: Do not heat the cover to install the cup. Heating the cover will damage the seal.
27. Install cup and shim using Right Bearing Race Installer J44875 and a handle.
28. Install axle shaft oils, seal (2) to side cover (1) using J29162 Output Shaft Seal Installer.
IMPORTANT: Grease the seal lips to protect the seal and to ease in assembly.
29. Install carrier assembly (1) to housing.
IMPORTANT: Do not apply excess sealer. Excess sealer could cause premature failure.
30. Apply a 2 - 3 mm (0.08 - 0.12 inch) amount of sealer GM P/N 1052942 or equivalent to the housing (1).
IMPORTANT: Grease the seal lips to protect the seal and to ease in assembly.
31. Install side cover (1) and bolts (2 and 3) to the housing. There is not a specific tightening sequence, but bolts with dowel pins should be tightened first. Alternate the others from side-to-side.
Torque:
Side Cover Bolts: 34 Nm (25 ft. lbs.)
32. Apply sealant GM P/N 12346004 or equivalent to threads of drain plug.
33. Install drain plug (1) into housing.
Torque:
Drain Plug: 24 Nm (18 ft. lbs.)
34. Fill transfer case with 500 ml. (17 oz.) gear oil GM P/N 12378514 or equivalent, or until lube is at bottom of lube fill hole.
35. Install sealant GM P/N 12345493 or equivalent to the threads of the fill plug (1).
36. Install fill plug (1) to side cover.
Torque:
Fill Plug: 15 Nm (11 ft. lbs.)