Intermediate Shaft Bearing Assembly Assemble S4WD

Special Tools

1. Install the inner shaft bearing, print side out, into the intermediate shaft bearing housing inner case half using the J 45232 (2) and the J 8092 (1).



2. Install the inner shaft bearing, print side out, into the intermediate shaft bearing housing outer case half using the J 45232 (2) and the J 8092 (1).



3. Install the inner axle bearing, print side out, into the intermediate shaft bearing housing outer case half using the J 45232 (2) and the J 8092 (1).



4. Install the thrust washer.



5. Install the inner clutch fork gear.



6. Install the clutch fork spring.



7. Install the washer.



8. Install the clutch fork and clutch fork sleeve.



9. Install the outer clutch fork gear.



10. Install the thrust washer to the outer intermediate shaft bearing housing case half.

Use grease to hold the thrust washer in place.

11. Apply a bead of sealant, GM P/N 1052942 or equivalent, to the sealing surface of one side of the intermediate shaft bearing housing case.
12. Install the outer intermediate shaft bearing housing case to the inner intermediate shaft bearing housing case.

Caution: Refer to Fastener Caution in the Preface section.




13. Install the intermediate shaft bearing case bolts and tighten to 48 N·m (35 lb ft)
14. Install the new inboard, oil pan side, seal on top of the seal bore.



15. Install the new seal using the J 45225 (2) and the J 8092 (1).




Caution: The outboard intermediate shaft bearing assembly seal must be installed 0.9-1.1 mm (0.035-0.043 in) below the surface of the intermediate shaft bearing assembly housing bore. If the seal is not installed properly, damage to the seal may occur.

16. Install the new seal using the J 45359  (2) and the J 8092 (1).



17. Pack the cavity of the inner intermediate shaft bearing housing with 55-65 cc (1.86-2.20 oz) of grease, GM P/N 12377985 or equivalent.



18. Install the actuator.
19. Install the actuator bolts and tighten to 6 N·m (53 lb in)

Intermediate Shaft Bearing Assembly Assemble A4WD

Special Tools

1. Install the inner shaft bearing, print side out, into the intermediate shaft bearing inner case half using the J 45232 (2) and the J 8092 (1).



2. Install the inner shaft bearing, print side out, into the intermediate shaft bearing outer case half using the J 45232 (2) and the J 8092 (1).



3. Install the inner shaft bearing (print side out) into the intermediate shaft bearing outer case half using the J 45232 (2) and the J 8092 (1).



4. Install the thrust washer.



5. Install the clutch fork sleeve.



6. Install the thrust washer to the outer intermediate shaft bearing case half.

Use grease to hold the thrust washer in place.

7. Apply a bead of sealant, GM P/N 1052942 or equivalent, to the sealing surface of one side of the intermediate shaft bearing housing case.
8. Install the outer intermediate shaft bearing housing case to the inner intermediate shaft bearing housing case.

Caution: Refer to Fastener Caution in the Preface section.




9. Install the intermediate shaft bearing case bolts and tighten to 48 N·m (35 lb ft)
10. Install the new inboard, oil pan side, seal on top of the seal bore.



11. Install the new seal using the J 45225 (2) and the J 8092 (1).




Caution: The outboard intermediate shaft bearing assembly seal must be installed 0.9-1.1 mm (0.035-0.043 in) below the surface of the intermediate shaft bearing assembly housing bore. If the seal is not installed properly, damage to the seal may occur.

12. Install the new seal using the J 45359  (2) and the J 8092 (1).



13. Pack the cavity of the inner intermediate shaft bearing housing with 55-65 cc (1.86-2.20 oz) of grease, GM P/N 12377985 or equivalent.
14. Install the intermediate shaft bearing plug.