Transfer Case Assemble

Tools Required 

• J 5590  Crankshaft Sprocket Installer
• J 8001  Dial Indicator Set
• J 36797  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 or equivalent. Components in the hypoid gear portion of the transfer case should be lubricated with GM P/N 12378514.

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.
   Fig 1: Assembling Differential Carrier

   
4. Install the side gears (2), pinion gears (3), and washers (1 and 4) to the carrier, if required.
   Fig 2: Installing Side Gears, Pinion Gears & Washers

   
5. Install the shaft (1) and roll pin (2) to the carrier, if required.
   Fig 3: Installing Shaft & Roll Pin To Differential Carrier

   
6. Use the J 44908  (1) and a hydraulic press in order to install the outer bearing race to the extension housing.
   Fig 4: Installing Outer Bearing Race To Extension Housing

   
7. Use the J 44908  (1) and a hydraulic press in order to install the inner bearing race to the extension housing.
   Fig 5: Installing Inner Bearing Race To Extension Housing

   
8. Measure the distance between the flange on the driven shaft and the end of the pinion. Record the value as dimension B.
   Fig 6: Measuring Distance Between Flange On Driven Shaft & End Of Pinion

   
9. Use the J 44907  (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft.
   Fig 7: Installing Inner Bearing To Drivenshaft

   
10. Install the drivenshaft (9), NEW spacer (5), and bearing (3) into the extension housing (6).
    Fig 8: Installing Drivenshaft, Spacer & Bearing Into Extension Housing

    
11. Use the J 5590  (1) and a hydraulic press in order to install the bearing onto the shaft.
    Fig 9: Using Hydraulic Press & Crankshaft Sprocket Installer To Install Bearing

    
12. Use the J 36797  (1) in order to install a new oil seal (2) into the extension housing (3).
    Fig 10: Installing Extension Housing Oil Seal

    
13. Lightly lubricate the splines of the drivenshaft with grease.
14. Install the flange (1) onto the shaft using a hydraulic press.
    Fig 11: Installing Extension Housing Flange

    
15. Install the extension housing assembly (3) and bolts (1) to the J 44755  (2).

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

    Fig 12: Installing Extension Housing Assembly To Holding Fixture

    
16. Install a new nut (1) onto the shaft.

    Tighten 

    • Tighten the nut, with new bearings to 250 N.m (185 ft lbs).
    • Tighten the nut, with used bearings to 200 N.m (148 ft lbs).
    Fig 13: Installing New Output Drivenshaft Nut

    
17. Remove the extension housing assembly and bolts from the J 44755  .
18. 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 N.m (13 in 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.
    Fig 14: Measuring Rotating Torque Of Drivenshaft

    
19. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.
    Fig 15: Measuring Distance Between End Of Pinion & Extension Housing Seal Surface

    
20. Install the J 44757-3 (2) into the bore of the housing (1).
    Fig 16: Installing Shim Selection Kit Into Bore Of Housing

    
21. Install J 44757-9 (3) and bolts (2) to the housing (1).

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

    Fig 17: Installing Shim Selection Kit Plate Onto Housing

    
22. Measure the distance (1) between the J 44757-3 and the J 44757-9 using a feeler gauge. Add the measured value (1) to 67.3 mm (2.65 in). Record the value as dimension "D".
    Fig 18: Determining Dimension "D"

    
23. 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.

    Fig 19: Determining Drivenshaft Value

    
24. Calculate the extension housing shim thickness. Refer to Extension Housing Shim Calculation Table .
25. Use the J 5590  (1) and a hydraulic press in order to install the bearings onto the idler gear.
    Fig 20: Installing Bearings Onto Idler Gear

    
26. Use the J 44752  (1) and a hydraulic press in order to install the bearing race into the cover-left.
    Fig 21: Installing Bearing Race Into Left Cover

    
27. Install the idler gear (2) and bearing race (1) to the case-left.
    Fig 22: Installing Idler Gear & Bearing Race

    
28. Inspect the gear for proper installation. The side of the gear with the long flange area (1) should be installed to the case-right side.
    Fig 23: Inspecting Idler Gear For Proper Installation

    
29. Install the J 44757-1  (1) to the idler gear and race.
    Fig 24: Installing Shim Selection Kit To Idler Gear & Race

    
30. Install the cover-right (1), bolts (2), and J 44757-8 (3) to the case-left.

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

    Fig 25: Installing Right Cover

    
31. Using a feeler gauge, measure the gap (1) in the J 44757-1  . The measured amount is the idler gear bearing shim thickness.
32. Disassemble the case-right and tools from the case-left.
    Fig 26: Determining Idler Gear Bearing Shim Thickness

    
33. Install the selected idler gear bearing shim (2) and bearing race (1) to the case-right.
    Fig 27: Installing Selected Idler Gear Bearing Shim & Bearing Race To Right Case

    
34. Use the J 44752  (1) and a hydraulic press in order to install the bearing race to the case-right.
    Fig 28: Installing Bearing Race To Right Case

    
35. Install the driveshaft bearing (3) to the case-right.
    Fig 29: Installing Driveshaft Bearing To Right Case

    
36. Use the J 44753  (1) and a hydraulic press in order to install the bearing to the case-right.
    Fig 30: Installing Bearing To Right Case

    
37. Use the J 44753  (1) to install the oil seal-transaxle side (2) to the case-left. Install until the seal bottoms in the case-left bore.
    Fig 31: Installing Oil Seal (Transaxle Side) To Left Case

    
38. Use the J 44753  (1) to install the oil seal-gear oil side (2) to the case-left. Install until the tool bottoms against the case-left.
    Fig 32: Installing Oil Seal (Gear Oil Side) To Left Case

    
39. Use the J 44908  (1) and a hydraulic press in order to install the bearing races to the case-left.
    Fig 33: Installing Bearing Races To Left Case

    
40. Use the J 44907  (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft.
    Fig 34: Installing Inner Bearing To Driveshaft

    

    Important:  The J 44757-7 shim is installed to create measurable end play and to assist in determining the proper size shim for bearing preload.

41. Assemble the shaft (1), J 44757-7 shim (5), and bearing (7) to the case-left.
    Fig 35: Assembling Output Driveshaft

    
42. Use the J 5590  (1) and a hydraulic press in order to install the shaft, J 44757-7  shim, and bearing to the case-left.
    Fig 36: Installing Output Driveshaft, Shim & Bearing To Left Case

    
43. Install the J 44757-2 (5) onto the driveshaft. Tighten until snug.
44. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), and nuts and washers (3) to the case-left.

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

45. Rotate the driveshaft, multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
    Fig 37: Installing Shim Selection Kit

    
46. Install J 8001  (3) onto the J 44757-6. Position the tip (2) of the indicator onto the end of the J 44757-2.
    Fig 38: Installing Dial Indicator

    
47. Tighten the nut (4) of the J 44757-2 to preload to the bearings and position the shaft at the bottom of travel. Use a second wrench to hold the J 44757-2 shaft. Observe the needle on the dial. When the needle movement stops, the shaft is at bottom of travel.
48. Zero the dial indicator.
49. Loosen and back-off the nut (4).
50. Tighten the nut (1) to preload the bearings and position the shaft at the top of travel. Use a second wrench to hold the J 44757-2 shaft.
51. Record the measured value on the dial indicator. Subtract the measured value from 6.0 mm (0.236 in) in order to determine the driveshaft shim required for proper bearing installation and preload.
52. Disassemble the shaft (1), bearing (7), and J 44757-7 shim (5) from the case-left.
    Fig 39: Disassembling Output Driveshaft

    
53. Install the proper size shim (5), shaft (1), bearing (7), and gear (8) to the case-left.
54. Lightly lubricate the splines of the driveshaft with grease.
55. Use the J 5590  (1) and a hydraulic press in order to install the bearing, proper size shim, and gear (2) onto the shaft.
    Fig 40: Installing Bearing, Shim & Gear Onto Output Driveshaft

    
56. Install the case-left (2) onto the J 44755  (1). Align the notched area of the tool with the flat areas of the driveshaft.
    Fig 41: Installing Left Case Onto Holding Fixture

    
57. Install a new nut (1) onto the driveshaft.

    Tighten 

    Tighten the nut to 505 N.m (372 ft lbs).

    Fig 42: Installing New Driveshaft Nut

    
58. Measure the rotating torque of the driveshaft. A properly assembled shaft and bearings should have a rotating torque of 1.5 N.m (13 in lbs).
59. Use the J 44752  (1) and a hydraulic press in order to install the carrier bearing race-inner to the case-right.
    Fig 43: Installing Carrier Bearing Race (Inner) To Right Case

    
60. Use the J 44752  (1) and a hydraulic press in order to install the carrier bearing race-outer to the case-right.
    Fig 44: Installing Carrier Bearing Race (Outer) To Right Case

    
61. Use the J 44752  (1) and a hydraulic press in order to install the bearing-inner to the differential carrier.
    Fig 45: Installing Bearing (Inner) To Differential Carrier

    

    Important:  The J 44757-4 shim is installed to create measurable end play and assist in determining the proper size shim for bearing preload.

62. Install the carrier (8), J 44757-4 shim (6), and bearing (2) to the case-right.
    Fig 46: Installing Carrier To Right Case

    
63. Use the J 44752  (1) and a hydraulic press in order to install the carrier, J 44757-4 shim, and bearing to the case-right.
    Fig 47: Pressing Carrier, Shim & Bearing Into Right Case

    
64. Install the case-right (1) onto the J 44755  (2). Position the carrier onto the post of the fixture.
    Fig 48: Installing Right Case Onto Holding Fixture

    
65. Install the J 44757-5 (5) onto the carrier. Tighten until snug.
    Fig 49: Installing Shim Selection Kit Onto Right Case

    
66. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), nuts and washers (3), and nuts (6) to the case-right.

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

67. Rotate the differential carrier multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
68. Install J 8001  (3) onto the J 44757-6  . Position the tip (2) of the indicator onto the end of the J 44757-5  .
    Fig 50: Installing Dial Indicator

    
69. Tighten the nut (4) of the J 44757-5 to preload to the bearings and position the differential carrier at the bottom of travel. Use a second wrench to hold the J 44757-5 shaft. Observe the needle on the dial. When the needle movement stops, the carrier is at bottom of travel.
70. Zero the dial indicator.
71. Loosen and back-off the nut (4).
72. Tighten the nut (1) to preload the bearings and position the carrier at the top of travel. Use a second wrench to hold the J 44757-5 shaft.
73. Record the measured value on the dial indicator. Subtract the measured value from 10 mm (0.394 in) in order to determine the carrier shim required for proper bearing installation and preload.
74. Disassemble the carrier (8), bearing (2), and J 44757-4 shim (6) from the case-right.
    Fig 51: Disassembling Right Case

    
75. Install the proper size shim (6), carrier (8), and bearing (2) to the case-right.
76. Use the J 44752  (1) and a hydraulic press in order to install the shaft, proper size shim, and bearing to the case-right.
    Fig 52: Assembling Right Case

    
77. Install the nut (1) to the differential carrier.

    Tighten 

    Tighten the nut to 500 N.m (369 ft lbs).

    Fig 53: Installing Differential Carrier Nut

    
78. Measure the rotating torque of the carrier. A properly assembled carrier and bearings should have a rotating torque of 1.5 N.m (13 in lbs).
79. Using a punch, stake the flange of the nut to the groove in the carrier shaft.
80. Use the J 44752  (1) in order to install the seal (2) to the case-right.
    Fig 54: Installing Right Case Seal

    
81. Remove the case-right (1) and carrier from the J 44755  (2).
    Fig 55: Removing Right Case From Holding Fixture

    
82. Install a random size shim (3), housing (2), and bolts (1 and 4) to the case-left.

    Tighten 

    • Tighten the M8 bolts to 32 N.m (24 ft lbs).
    • Tighten the M10 bolts to 56 N.m (41 ft lbs).
      Fig 56: Installing Output Driveshaft Housing & Shim To Left Case

      
83. Apply sealant GM P/N 12346004 or equivalent to both sides of the shim (2).
84. Install the housing (1), selected shim (2), and bolts (3) to the housing.

    Tighten 

    Tighten the bolts to 32 N.m (24 ft lbs).

    Fig 57: Installing Extension Housing & Shim To Output Driveshaft Housing

    
85. Install an M8 x 1.25 bolt (1) into a threaded hole in the flange.
86. Position the top of J 8001  (2) against the flat area of the bolt.
    Fig 58: Positioning Dial Indicator To Measure Backlash

    
87. Install a wrench or socket onto the nut (1) of the driveshaft. Do not allow the shaft to rotate or move when measuring backlash.
88. Rotate the flange (2) left and right in order to measure the drive and driven shafts gear backlash. Measure the backlash in multiple locations. The correct gear backlash is 0.2-0.3 mm (0.0078-0.0118 in).
    Fig 59: Measuring Backlash

    
89. Select and install the correct shim (4) to obtain the proper backlash. A change in shim thickness has a one-to-one ratio and change in gear backlash.
    • A thicker shim will increase backlash.
    • A thinner shim will decrease backlash.
90. Install a new O-ring (5) during final assembly.
    Fig 60: Adjusting Backlash

    
91. Apply sealant GM P/N 12346004 or equivalent to the sealing surfaces of the case-right.
92. Install the idler gear (1) to the case-right.
    Fig 61: Installing Idler Gear To Right Case

    
93. Install the idler gear into the case-right. The side of the gear with the long flange area (1) should be installed to the case-right.
    Fig 62: Identifying Long Flange Area Of Idler Gear

    
94. Rotate the J 44755  90 degrees.
95. Install the case-right (2) to the case-left (1).
    Fig 63: Installing Right Case To Left Case

    
96. Install the bolts (1) to the case.

    Tighten 

    Tighten the bolts to 60 N.m (44 ft lbs).

    Fig 64: Installing Case Bolts

    
97. Install the speed sensor (1) and O-ring.
    Fig 65: Installing Speed Sensor & O-Ring

    
98. Install the hose and clamp (1), vent hose (2), and bolt (3).

    Tighten 

    Tighten the vent hose/speed sensor bolt to 10 N.m (106 in lbs).

    Fig 66: Installing Vent Hose

    
99. Install the transmission oil drain plug (1) and gasket.

    Tighten 

    Tighten the drain plug to 32 N.m (24 ft lbs).

    Fig 67: Installing Transmission Oil Drain Plug & Gasket

    
100. Install the gear oil drain plug (1) and gasket.

     Tighten 

     Tighten the drain plug to 32 N.m (24 ft lbs).

     Important:  The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer (located behind the transmission sun gear). The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components (excluding gaskets and seals) are replaced.

     Fig 68: Installing Extension Housing Drain & Fill Plugs

     
101. Perform the transfer case selective washer measurement procedure as required. Refer to TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK .