Assemble

Transfer Case Assemble

- Tools Required
- DT 46429 Oil Seal Driver
- DT 46512 Seal Installer
- EN 46342 Driver Handle
- J 44873 Pinion Flange Holder and Remover





1. Lubricate all internal components with GM P/N 12578261 (Canadian P/N 10953455) prior to assembly.
2. Use the EN 46342 (1) and the DT 46429 (2) in order to install the bearing (207) and seal (301).





3. Install the output shaft (201) with bearing, NEW collapsible spacer (204) and washers (215). Note the proper installation direction of the spacer(204).





4. Lubricate the threads of the output shaft with GM P/N 12378261 (Canadian P/N 10953455).
5. Install the output yoke (208), NEW O-ring (302), NEW sealing washer (303), NEW washer (209) and NEW locknut (210).





6. Secure the case in a vise with soft jaws.

Notice: Refer to Fastener Notice in Cautions and Notices.

7. Install the J 44873 and bolts.
- Tighten the bolts to 48 Nm (35 ft. lbs.).

Important: Rotate the output yoke several times in both directions to seat the tapered roller bearings prior to measuring the rotating torque.

8. Tighten the locknut to 108 - 294 Nm (75.6 - 217 ft. lbs.) while measuring the rotating torque. Tighten the nut to achieve a rotating torque of 1.15 - 1.71 Nm (10.2 - 15.1 inch lbs.).
- If the rotating torque exceeds 1.71 Nm (15.1 inch lbs.), replace the collapsible spacer and reassemble.
- If the locknut tightening torque exceeds 294 Nm (217 ft. lbs.), replace the collapsible spacer and reassemble.





9. Remove the J 44873 and bolts.
10. Stake the locknut using a 3.5 mm (0.138 inch) punch.





11. Install the input gear (214) with shim (216) and bearing (217) into the case.





12. Use the EN 46342 (1) and the DT 46512 (2) in order to install the oil seal into the cover. Install the seal until the flat surface of the seal measures 0.00-1.0 mm (0.00-0.04 inch) flush with or slightly above the surface of the cover (a).





13. Install a NEW O-ring (304) to the cover.
14. Install the cover (101) and bolts (102).
- Tighten the bolts to 26 Nm (20 ft. lbs.).
15. Install the locating pin (105).





16. Install the fill plug (401) and NEW washer (402).
17. Install the drain plug (403) and NEW washer (404).
- Tighten the drain plug to 44 Nm (33 ft. lbs.).





18. Install the ventilation valve (408), hose (407) and clamps (406).
19. Recheck the unit for proper assembly.