GM Service Manual Online
For 1990-2009 cars

Installation Procedure

Tools Required

    • J 37758 Countershaft Rear Plug Installer
    • J 8092 Driver Handle
    • J 37750 Oil Seal Installer
    • J 36850 Transjel® Transmission Assembly Lubricant

    Object Number: 153203  Size: SH
  1. Install the rear countershaft plug (1) into the rear case (2) using the J 37758 and the J 8092 and a hammer.

  2. Object Number: 153209  Size: SH
  3. Install the new rear case oil seal (1) into the rear case (2) using the J 37750 and a hammer.
  4. Apply the J 36850 to the new rear case oil seal lip.
  5. Apply the GM P/N 12346240, or equivalent, to the transmission rear case mating surface.
  6. 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.

  7. Install the rear case to the transmission and secure with the twelve bolts.
  8. Tighten
    Tighten the rear case bolts to 28 N·m (20 lb ft).

  9. Install the transfer case into the vehicle.
  10. Install the gearshift lever case to the transmission. Refer to Gearshift Lever Case Installation
  11. Add approximately 1.5 liters (1.6 quarts) of 75W-90 GL4 lubricant or equivalent, into the transmission oil level/filler plug hole. The oil level should be even with the bottom of the transmission oil level/filler plug hole.
  12. Apply the GM P/N 12346004, or equivalent, to the threaded portion of the transmission oil level/filler plug.

  13. Object Number: 168125  Size: SH
  14. Install the transmission oil level/filler plug (2) into the transmission.
  15. Tighten
    Tighten the transmission oil level/filler plug to 28 N·m (20 lb ft).