Tools Required

1. Install the needle bearings to the mainshaft.

Ensure the needle bearing is installed with the numbered side of the bearing facing the bearing installer tool.

2. Install the retainer ring onto the pump cover.
3. Install the oil pump pickup to the pickup tube.
4. Install the pickup tube to the oil pump body.
5. Install the oil pump pickup to the oil pump body.
6. Install the retainer to the oil pump body.
7. Secure the oil pump drive gear and the oil pump driven gear into the oil pump body.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Secure the oil pump cover to the oil pump with the oil pump cover bolts.

Tighten
Tighten the oil pump cover bolts to 10 N·m (89 lb in).




9. Install the compression spring to the lockup collar.
10. Install the lockup hub onto the compression spring and lockup collar.
11. Install the synchronizer hub snap ring.
12. Using J 37668 , install the rear output shaft seal to the rear bearing retainer.



13. Using J 8092 and J 33832 , install the front output bearing to the front case.



14. Install the front output bearing snap ring to the front case.
15. Using J 37668 , install the front output shaft seal to the front case.
16. Using J 8092 andJ 33832 , install the rear output bearing to the rear case.



17. Using J 8092 and J 29169 , install the front input bearing to the front case.



18. Install the front input bearing snap ring to the front case.



19. Install the selector to the front case.
20. Install the detent spring to the front case.
21. Install the detent roller to the front case.
22. Install the selector shaft into the case.
23. Align the selector shaft with the spline on the selector.
24. Connect the retainer clip to the selector shaft.



25. Position the power take off (PTO) drive gear onto the planetary gear.
26. Install the PTO drive gear and planetary gear into the front case.



27. Install the input carrier snap ring onto the input carrier.
28. Using J 37668 install the input shaft front oil seal into the front case.



29. Install the annulus gear into the front case.



30. Install the annulus gear snap ring to the front case. The open end of the snap ring should be positioned toward the shift shaft.



31. Install the range fork and the shift shaft hub.

•	Align the shift shaft hub onto the carrier assembly.

•	Align the shift fork pin to the slot in the selector.

32. Install the shift rail through the range fork and into the boss in the front case.
33. Apply a thin layer of RTV sealer GM P/N 12345739 to the front case half.



34. Install the mainshaft and the oil pump onto the carrier assembly and output shaft bearing.

Ensure the wide spline of the shaft is aligned with the wide slot in the hub.




35. Install the drive chain, driven gear, and the drive gear onto the output shaft.

35.1.

Position the drive chain onto the driven gear and drive gear.

35.2.

Install the drive chain, driven gear, and drive gear as an assembly.

35.3.

Install the drive chain, driven gear, and drive gear onto the output shaft and in the front case.




36. Assemble the synchronizer and the mode shift fork.
37. Align the synchronizer to the mainshaft drive gear.
38. Align the mode fork to the shift rail.
39. Install the synchronizer hub to the synchronizer hub assembly.



40. Install the clutch coil housing onto the mainshaft.
41. Install the clutch coil housing snap ring onto the main shaft.

Ensure the flat side of the clutch coil housing snap ring is positioned toward the clutch coil housing.

42. Install the shift rail spring onto the shift rail.
43. Install the clutch coil to the rear case.



44. Install the clutch coil wire through the rear case.

Secure the wire connector to the clutch coil wire.

45. Install the clutch coil nuts to the clutch coil.

Tighten
Tighten the clutch coil nuts to 10 N·m (84 lb in).

46. Apply a thin bead of RTV sealer GM P/N 12345739 or equivalent onto the pump body and case mating surfaces.
47. Using hole located at the 12 o'clock position, secure the bracket to the transfer case with the case bolt.
48. Secure the front and rear case halves together with the case bolts.

Tighten
Tighten the case bolts to 41 N·m (30 lb ft).




49. Install the rear output bearing snap ring onto the mainshaft.

Ensure the flat side of the snap ring is positioned toward the transfer case.

50. Install the tone ring stop retainer ring.
51. Using J 5590 , install the speedometer tone wheel onto the mainshaft.
52. Apply a thin bead of RTV sealer GM P/N 12345739 or the equivalent to the bearing retainer mating surface.
53. Secure the bearing retainer to the rear case with the bolts.

Tighten
Tighten the case bolts to 41 N·m (30 lb ft).

54. Install the four wheel drive indicator switch to the front case.

Tighten
Tighten the switch to 27 N·m (20 lb ft).

55. Secure the speed sensor to the transfer case with the bolt.

Tighten
Tighten the speed sensor bolt to 16 N·m (12 lb ft).




56. Secure the output yoke, rubber sealing washer, and flat washer to the rear output shaft with the nut.

Tighten
Tighten the nut to 170 N·m (230 lb ft).

57. Secure the output yoke, rubber sealing washer, and flat washer to the front output shaft with the nut.

Tighten
Tighten the nut to 224 N·m (304 lb ft).