GM Service Manual Online
For 1990-2009 cars only

Special Tools

    • J 5590 Pinion Bearing Race Installer - Rear
    • J 8092 Driver Handle
    • J 24433 Pinion Cone and Side Bearing Installer
    • J 36850 Transjel Lubricant
    • J 46268 Output Seal Installer
    • J 46269 Input Seal Installer

    Object Number: 926999  Size: SH

    Important: 

       • Lubricate all bearings and bearing journals with transfer case fluid during installation.
       • Use a hammer and a brass drift only on the outer bearing race.
       • Ensure the bearing is kept square to the bore while installing.

  1. Install the input shaft bearing (117) into the case (1).

  2. Object Number: 927003  Size: SH

    Important: 

       • Use a hammer and a brass drift only on the outer bearing race.
       • Ensure the bearing is kept square to the bore while installing.

  3. Install the front output shaft bearing (113) into the case (1).

  4. Object Number: 927008  Size: SH
  5. Using the J 46269  (2) and the J 8092  (1), install the input shaft oil seal (13).

  6. Object Number: 927013  Size: SH
  7. Using the J 46268  (2) and the J 8092  (1), install the front output shaft oil seal (14).
  8. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 925600  Size: SH

    Important: While tightening the snubber bolts, position the snubber to the outside of the case, so when assembled, the snubber is in the farthest position away from the chain.

  9. Install the chain snubber (3).
  10. Apply sealant GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the bolts (4).
  11. Tighten
    Tighten the bolts to 7 N·m (62 lb in).


    Object Number: 925598  Size: SH
  12. Install the vent baffle (10).
  13. Apply sealant GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the bolt (9).
  14. Tighten
    Tighten the bolt to 7 N·m (62 lb in).


    Object Number: 1527336  Size: SH

    Important: The planetary differential gears are timed to the sun gears. If the gears are not timed properly, the differential will not rotate without binding - 40/60 ratio.

  15. With the thrust washer side of the planetary differential facing down, align the marks on the pinion gears. Position the alignment marks with an area on the planetary differential that can be reference for all gears.

  16. Object Number: 1463977  Size: SH

    Important: The input shaft (118) must be installed to the carrier (111) with the raised bosses (1) facing up and the thrust washer groove facing down. Reversing this causes a mis-build, and the wrong torque split of 60/40.

  17. Use a press to install the input shaft assembly to the carrier (111).

  18. Object Number: 1463979  Size: SH
  19. Lubricate the thrust washer (100) with J 36850 or equivalent.
  20. Install the thrust washer over the rear of the input shaft, into the groove of the carrier (111).
  21. Insert the sun gear (101) into the carrier.

  22. Object Number: 1527352  Size: SH
  23. If the pinion gears are properly aligned, the sun gear (101) carrier assembly will rotate freely.
  24. Remove the sun gear (101) from the carrier (111).

  25. Object Number: 925596  Size: SH
  26. Assemble the front output shaft (112) to the case (1).
  27. Assemble the snap ring (114).

  28. Object Number: 1463986  Size: SH
  29. Assemble the chain (109), upper gear of the planetary assembly, and lower sprocket (115) to the case (1).

  30. Object Number: 1463989  Size: SH
  31. Use the J 5590 and a press to fully seat the lower sprocket (115) to the front output shaft, while guiding the input shaft of the planetary assembly, until it is seated to the case.

  32. Object Number: 927017  Size: SH

    Important: 

       • Use a hammer and a brass drift only on the outer bearing race.
       • Ensure the bearing is kept square to the bore while installing.

  33. Install the rear output shaft bearing (104).

  34. Object Number: 927020  Size: SH
  35. Using the J 46268  (2) and the J 8092  (1), install the rear output oil seal (7).

  36. Object Number: 927024  Size: SH

    Important: 

       • Use a hammer and a brass drift only on the outer bearing race.
       • Ensure the bearing is kept square to the bore while installing.

  37. Install the inner output shaft bearing (103).

  38. Object Number: 927026  Size: SH

    Important: 

       • Use a hammer and a brass drift only on the outer bearing race.
       • Ensure the bearing is kept square to the bore while installing.

  39. Install the front output shaft inner bearing (116).

  40. Object Number: 925628  Size: SH
  41. Install the rear output shaft (106) by pushing it in through the bearings.
  42. Install the rear output shaft snap ring (102) in the lower groove of the output shaft (106).

  43. Object Number: 1463976  Size: SH
  44. Use the J 24433 and a press to install the sun gear (101) to the output shaft.

  45. Object Number: 1527343  Size: SH

    Important: 

       • Ensure both the sealing surfaces on the case and cover are free of dirt, oil, and cleaning solvent.
       • Ensure the dowel pins (5) are installed in the cover (2).

  46. Install the dowel pins (5) into the cover (2), if necessary.
  47. Apply a 3.175 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541), or equivalent, to the mating surfaces of the cover (2).

  48. Object Number: 1463992  Size: SH
  49. Insert the dowel pin (3), if removed.
  50. Lower the cover (2) over the case (1). Turn the rear output shaft in order to align the splines and the shaft into the bearing in the cover.

  51. Object Number: 927059  Size: SH

    Important: The bolts are self-tapping. They must be hand started. Do NOT use power-assisted tools to install the bolts (11).

  52. Install the case bolts (11).
  53. Tighten
    Tighten the case bolts to 25 N·m (18 lb ft) in a criss-cross pattern.


    Object Number: 927061  Size: SH
  54. Install the vent breather by pushing it into the hole. Align the flat on vent with the flat on the case.
  55. Lightly pull on the vent to ensure proper installation.

  56. Object Number: 927063  Size: SH
  57. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the drain plug (8).
  58. Install the drain plug (8).
  59. Tighten
    Tighten the drain plug to 25 N·m (18 lb ft).


    Object Number: 927064  Size: SH
  60. Fill the transfer case with manual transmission fluid GM P/N 88861800 (Canadian P/N 88861801). Fill to the bottom of fill plug threads. Ensure the vehicle is on a level surface. Refer to Approximate Fluid Capacities .
  61. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent, to the threads of the fill plug.
  62. Install the fill plug (6).
  63. Tighten
    Tighten the fill plug to 25 N·m (18 lb ft).


    Object Number: 1309861  Size: SH
  64. Install the dampener (300) and the bolts (16).
  65. Tighten
    Tighten the bolts to 27 N·m (20 lb ft).