Tools Required

1. If removed, install the transfer case mounting studs to the height of 29.5 mm-30.5 mm (1.16-1.20 in).



2. Attach the J 45759 to the front transfer case using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759 .
3. Install the J 45759  (2) into the J 3289-20  (1) and secure with the pivot pin.



4. Install the input bearing.




Important: Use only new retaining rings.

5. Install the input bearing retaining ring.



6. Install the front output shaft front bearing.
7. Install the front output shaft front bearing retaining ring.



8. Using the J 8092  (1) and the J 36370  (2), install the front output shaft rear bearing.



9. Using the J 42737 , install the control actuator lever shaft bearing. The seal faces outward.



10. Lubricate the control actuator lever shaft bearing.
11. Install the control actuator lever shaft.



12. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.



13. Using the J 22873 and a hydraulic press, install the tone wheel on the front output shaft.



14. Install the front output shaft assembly. Use a soft-face hammer to tap the front output shaft in the bearing.



15. Install the front output shaft retaining ring.



16. Lubricate the thrust washer for the input shaft with J 36850 or equivalent.
17. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.



18. Using the J 8092  (1) and the J 45383  (2), install the pilot bearing in the input shaft.



19. Install the input shaft assembly.



20. Lubricate the input shaft thrust washer with J 36850 or equivalent.
21. Install the input shaft thrust washer.




Important: When installing the carrier lock plate in the planetary carrier , ensure that the lettering is facing up.

22. Lubricate the carrier lock plate with J 36850 or equivalent.
23. Install the carrier lock plate.



24. Install the retaining ring for the planetary gear shaft.



25. Install the planetary gear carrier. Use a soft-face hammer to tap the input gear in the bearing.



26. Install the outer retaining ring for the input gear bearing.



27. Install new shift fork pads, if removed.
28. Install the range shift sleeve in the range fork.



29. Align the range shift sleeve on the planetary carrier.
30. Align the roller on the range fork in the control actuator lever slot.
31. Install the range shift fork.




Important: Install the shift fork shaft in the range fork assembly, with the machined hole facing the bottom of the front case half.

32. Install the shift fork shaft.



33. Install the clutch lever assembly.




Important: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.

34. Install new O-ring seals on the clutch lever pivot pins.
35. Lubricate the O-ring seals with transfer case fluid.
36. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the clutch lever pivot pin threads.

Notice: Refer to Fastener Notice in the Preface section.

37. Install the clutch lever pivot pins with the aluminum washers and O-ring seals in the front case half.

Tighten
Tighten the clutch lever pivot pins to 61 N·m (45 lb ft).





Important: Ensure that the shift detent plunger is seated correctly on the control actuator lever.

38. Install the shift detent plunger.
39. Install the shift detent spring.
40. Lightly lubricate a NEW shift detent plunger O-ring seal with transfer case fluid.
41. Install the O-ring seal on the shift detent spring bolt.
42. Install the shift detent spring bolt in the front transfer case.

Tighten
Tighten the shift detent spring bolt to 17 N·m (13 lb ft).





Important: The following service procedure is to be performed only if the rear output shaft is new.

43. Install the rear output shaft oil restrictor flush with the end of the shaft.




Important: In order to position the bearing at the proper depth, ensure that the double shoulder of the J 36370 is against the bearing.

44. Install the clutch housing bearing, using the J 8092  (1) and the J 36370  (2).



45. Clamp the rear output shaft in a soft-jaw vise with the front end facing up.
46. Install the clutch housing on the rear output shaft.




Important: If replacing a 1st design clutch hub or 1st design clutch pressure plate with the 2nd design components, replace both the clutch hub and the clutch pressure plate. The 2nd design components have different dimensions than the 1st design. The clutch will not function properly if both components are not the same design level.

47. Install the 1st design (1) or 2nd design (2) clutch hub.




Important: The fingers of the clutch hub oil restrictor plate face up.

48. If 1st design, install the clutch hub oil restrictor plate.



49. If 1st design, install the clutch backing plate in the clutch housing, with the step shoulder facing down.



50. Install a friction clutch pressure plate.
51. Install a steel clutch pressure plate.
52. Continue to install the friction and the steel clutch plates, alternating until 8 friction plates and 7 steel plates are installed.



53. Install the clutch hub retaining ring.




Important: 

•	A clutch plate shim package is necessary in order to have the proper shims available for setting up the clutch pack. Improper shimming can cause driveability concerns and failure of the transfer case.

•	The 2nd design clutch components will have a different stack-up height. The J 44295-4 (3) must be used with the 2nd design clutch components.

54. Securely install the base plate (4) of the J 44295 in a vise with the machined surface of the locating tabs facing up.
55. Install the assembled rear output shaft with the clutch housing, the inner clutch plates, and the outer separator plates on the base plate (4) of the J 44295 .
56. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
57. Place the gage block (2) of the J 44295 on 1 of the locating tabs of the base plate (4) of the J 44295 .
58. If 1st design clutch components, using a feeler gage, measure between the gage block (2) and the weight (1) of the J 44295 .
59. If 2nd design clutch components, place the spacer (3) of the J 44295 under the gage block (2) of the J 44295 .
60. If 2nd design, using a feeler gage, measure between the gage block (2) and the spacer (3).
61. Measure with the gage block (2), the spacer (3) if 2nd design, and the feeler gage on the remaining 2 locating tabs of the base plate (4).

Important: The specification is the average clearance remaining between the gage block (2) and the weight (1) or shim (3).

62. The average of the 3 measurements is the required shim thickness.

Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.

63. Select, from the clutch plate shim package, the correct shim or shims plus or minus 0.10 mm (0.004 in). You may use a combination of 2 shims to obtain the correct thickness.

The shims in the clutch plate shim package are the following thickness:

•	0.30 mm (0.12 in)

•	0.56 mm (0.022 in)

•	0.81 mm (0.032 in)

•	1.04 mm (0.041 in)

•	1.30 mm (0.051 in)

•	1.55 mm (0.061 in)

•	1.80 mm (0.071 in)

•	2.08 mm (0.081 in)

64. Remove the weight (1) of the J 44295 .

Important: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then install the clutch plates again, it could change the measurement.

65. Install the shim or shims.



66. Using a suitable press plate and a hydraulic press, press the clutch bearing inner support in the clutch pressure plate bearing. Ensure the bearing inner bearing race is supported.



67. If 1st design, install the retaining ring in the clutch pressure plate.
68. If 1st design, install the clutch pressure plate bearing and bearing inner support in the clutch pressure plate.



69. If 2nd design, install the clutch pressure plate bearing, with the bearing inner support, in the clutch pressure plate.



70. If 1st design, install the clutch pressure plate spring.
71. If 1st design, align the tabs on the clutch pressure plate with the grooves in the clutch hub and install the clutch pressure plate assembly. Ensure the spring is installed in the groove of the pressure plate.



72. If 2nd design, install the clutch pressure plate spring.
73. If 2nd design, install the clutch pressure plate. Align the lugs of the pressure plate with the slots in the hub. The spring installs in the groove of the plate.



74. Install the clutch pressure plate retaining ring. Push down on the pressure plate to access the retaining ring groove.



75. Align the tab on the clutch bearing inner support between the clutch lever.
76. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
77. Install the rear output shaft assembly.




Important: Align the marks of the drive chain and sprockets, if using the chain and sprockets again.

78. Install the drive chain and sprockets. The blue chain links must face up, or toward the rear of the transfer case.



79. Install the drive sprocket retaining ring.



80. Install the driven sprocket retaining ring.



81. Install a new oil pump O-ring for the oil pump suction pipe in the oil pump.



82. Install the oil pump assembly.



83. If 1st design, install the oil pump screen.
84. If 1st design, install the connector on the oil pump screen.
85. If 1st design, install the oil pump suction pipe to the oil pump.
86. If 1st design, connect the oil pump suction pipe to the connector.



87. If 2nd design, install the oil pump suction pipe assembly.

87.1.

Install the screen in the case.

87.2.

Install the pipe to the oil pump.

87.3.

Inspect the O-ring for not being damaged and in the proper position.




88. Install the transfer case magnet.



89. Install the rear output shaft speed sensor reluctor wheel.




Important: Install the rear output shaft bearing, with the groove for the retaining ring, facing up.

90. Install the rear output shaft bearing.



91. Install the rear output shaft bearing retaining ring.



92. If necessary, install the oil pump wear sleeve.




Important: Ensure the locating pins are installed in the front case half.

93. Install the locating pins in the front case, if necessary.




Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

Important: Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.

94. Apply a 3 mm (1/8 in) bead of RTV sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.



95. Align the outside retaining ring, for the rear output shaft bearing, so that it is easily accessed through the opening in the rear case half.
96. Lower the rear case half into place.



97. Using a pair of snap ring pliers, open the retaining ring for the rear output shaft bearing.
98. Insert a rubber coated screwdriver into 1 of the speed sensor holes and lift up on the speed reluctor wheel, then seat the retaining ring.




Notice: This component is made of magnesium. Proper assembly is required to prevent damage. Ensure the magnesium transfer case housings are properly insulated from all external steel components, or galvanic corrosion will occur. Use only the transfer case bolts/studs with the cup style aluminum washer. Use only aluminum fill and drain plugs. Use only aluminum brackets under the case bolts. Ensure new seals are installed that have a rubber insulated outside diameter and have no tears or cuts. Extensive damage will occur if there is galvanic corrosion between the magnesium and steel components.

99. Install the case bolts/studs and the brackets.

Tighten

•	Tighten the case bolts, without brackets, to 37 N·m (27 lb ft).

•	Tighten the case bolts, with brackets, to 27 N·m (20 lb ft).




100. Install the access hole plug.



101. Install new O-ring seals on the vehicle speed sensors.
102. Lubricate the vehicle speed sensor O-ring seals with transfer case fluid.
103. Install the rear vehicle speed sensors.

Tighten
Tighten the speed senor to 15 N·m (11 lb ft).




104. Install the front vehicle speed sensor.

Tighten
Tighten the speed senor to 15 N·m (11 lb ft).




105. Install the actuator insulator to the transfer case.
106. Install the actuator encoder motor to the transfer case. Rotate the control actuator lever shaft to align to the encoder motor.
107. Install the mounting bolts for the actuator encoder motor.

Tighten
Tighten the actuator encoder motor mounting bolts, in the sequence shown, to 20 N·m (15 lb ft).




108. Install a new rear output shaft bushing, using the J 45380 .

108.1.

Install the bushing on the finger section of the J 45380 .

108.2.

Install the finger section to the main body of the J 45380 .

108.3.

Position the bushing and tool to the case.

108.4.

Using a hammer and the J 45380 , install the bushing.




109. Align the rear output shaft seal to the rear case, with the square tab up and the drain hole down.
110. Using the J 37668-A , install the rear output shaft seal.



111. Install the J 44636-2 on the transfer case front output shaft.



112. Install the transfer case front output shaft seal on the J 44636-2 .



113. Using the J 44636-1 , install the transfer case front output shaft seal.



114. Install the dust seal.



115. Using the J 42738 , install the front input shaft seal.