Tools Required

1. Remove the drain plug (1) from the extension housing. Allow the gear oil to drain.



2. Remove the drain plug (1) from the left case. Allow the transmission oil to drain.



3. Install the transfer case assembly (1) onto the J 44755  (3). Position the carrier onto the post of the fixture.

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.

4. Install the retaining bolts (2).

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




5. Remove the hose and clamp assembly (1), vent hose with bracket (2), and bolt (3).



6. Remove the extension housing assembly (1 and 3), bolts (2 and 6), shim (4) and O-ring (5). Mark or tag the shim for assembly.



7. Remove the bolts (1) from the case.




Important: When separating the case halves, avoid damage to the sealing surfaces. Do not insert a screwdriver or prying tool between the case sealing surfaces.

8. Rotate the J 44755 90 degrees.
9. Separate the right case (2) from the left case (1).



10. Remove the idler gear (1) from the right case.



11. Note the installed position of the idler gear. The side of the gear with the longer flange area (1) is to be installed to the right case.



12. Install the left case (2) onto the J 44755  (1). Align the notched area of the tool with the flat areas of the driveshaft.



13. Remove the nut (1) from the driveshaft.



14. Position the left case into a press.



15. Remove the gear (2), bearing (3), shim (4), and shaft (1) from the left case. Mark or tag the shim for assembly.



16. Use the J 44380  (2) and the SA9133T  (1) in order to remove the outer bearing race from the left case (3).



17. Remove the oil seals (1) from the left case.



18. Use the J 44753  (1) to install the oil seal - transaxle side (2) to the left case. Install until the seal bottoms in the left case bore.



19. Use the J 44753  (1) to install the oil seal - gear oil side (2) to the left case. Install until the tool bottoms against the left case.



20. Use the J 44908  (1) and a hydraulic press in order to install the outer bearing race to the left case.



21. Install the shim (2), shaft (1), and bearing (3).



22. Lightly lubricate the splines of the driveshaft with grease.
23. Use the J 5590  (1) and a hydraulic press in order to install the bearing, shim, and gear (2) onto the shaft.



24. Install the left case (2) onto the J 44755  (1). Align the notched area of the tool with the flat areas of the driveshaft.



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

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

26. Measure the rotating torque of the driveshaft. A properly assembled shaft and bearings should have a rotating torque of 1.5 N·m (13 lb in).



27. Install a new O-ring (5), shim (4), extension housing assembly (1 and 3) and bolts (2 and 6).

Tighten

•	Tighten the M8 bolts to 32 N·m (23 lb ft).

•	Tighten the M10 bolts to 60 N·m (44 lb ft).




28. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the sealing surfaces of the right case.
29. Install the idler gear (1) to the right case.



30. Install the idler gear into the right case. The side of the gear with the long flange area (1) should be installed to the right case.



31. Rotate the J 44755 90 degrees.
32. Install the right case (2) to the left case (1).



33. Install the bolts (1) and tighten as follows:

Tighten

•	Tighten the M8x40 case bolt (1) to 32 N·m (24 lb ft).

•	Tighten the M10x60 case bolts (2) to 60 N·m (44 lb ft)

•	Tighten the M10x50 case bolt (3) LY7 only to 60 N·m (44 lb ft)

•	Tighten the M10x75 case stud bolts (4) LY7 only to 60 N·m (44 lb ft)




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

Tighten
Tighten the vent hose/speed sensor bolt to 30 N·m (22 lb ft).




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

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




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

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

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.

37. Perform the transfer case selective washer measurement procedure as required. Refer to Transmission to Transfer Case End Play Check in Automatic Transmission - 4T65-E.
38. Refer to Installation and Fluid Fill in Transfer Case and/or Seal Replacement .