GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 3289-20 Holding Fixture
    • J 5590 Pinion Bearing Race Installer - Rear
    • J 8092 Universal Driver
    • J 22828 Input and Countershaft Race Installer
    • J 36373 Input Sun Gear Ball Bearing Installer
    • J 36850 Transjel Lubricant
    • J 42176 Universal Driver Handle - Non-Threaded
    • J 43484 Front Output Shaft Seal Installer
    • J 45540 Tone Ring and Bearing Installer
    • J 45756 Rear Output Shaft Seal Installer
    • J 45758 Input Seal Installer
    • J 45759 Assembly Fixture
    • J 45848 Bearing Installer

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 823238  Size: SH
  1. If removed, install the transfer case mounting studs.
  2. Tighten
    Tighten the mounting studs to 10 N·m (89 lb in).


    Object Number: 823195  Size: SH
  3. Attach the J 45759  (2) to the front case half using the adapter studs. All of the assembly procedures can be performed with the case mounted to the J 45759  (2).
  4. Install the J 45759  (2) into the J 3289-20  (1) and secure with pivot pin.

  5. Object Number: 823229  Size: SH
  6. If removed, apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the vent.
  7. Install the vent.
  8. Tighten
    Tighten the vent to 6 N·m (53 lb in).


    Object Number: 819637  Size: SH
  9. Install the front output shaft rear bearing in the rear case half.
  10. • Use a hammer and a brass drift only on the outer bearing race.
    • Ensure the bearing is kept square to the bore while installing.

    Object Number: 823239  Size: SH

    Important: Lubricate all bearings and bearing journals with transfer case fluid during installation.

  11. Install the input shaft bushing in the front case half using the J 36373 and a hammer.

  12. Object Number: 819641  Size: SH
  13. Install the front bearing for the front output shaft in the front case half.
  14. • Use a hammer and a brass drift only on the outer bearing race.
    • Ensure the bearing is kept square to the bore while installing.

    Object Number: 823240  Size: SH
  15. If removed, install the input shaft rear support bearing in the rear output shaft using J 42176  (1) and J 45848  (2).

  16. Object Number: 823241  Size: SH
  17. Using the J 22828 and a hydraulic press, install the rear output shaft bearing with the retaining ring groove towards the gear.

  18. Object Number: 823242  Size: SH
  19. Using the J 22828 and a hydraulic press, install a NEW speed reluctor wheel.

  20. Object Number: 823236  Size: SH
  21. Install a NEW retaining ring for the rear output shaft bearing.

  22. Object Number: 823232  Size: SH
  23. Install the rear output shaft in the annulus gear.

  24. Object Number: 823231  Size: SH

    Caution: The vehicle could roll while in park if the annulus gear becomes disengaged from the rear output shaft. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.

    Notice: Damage may occur to the viscous coupling if the retaining ring for the rear output shaft to the annulus gear fails or becomes dislodged during vehicle operation. Always install a new rear output shaft to annulus gear retaining ring. Ensure the rear output shaft retaining ring is fully seated in the annulus gear.

  25. Install a NEW annulus gear retaining ring.

  26. Object Number: 1266756  Size: SH
  27. Install the rear output shaft in the rear case.
  28. • Spread the rear output shaft rear bearing outer retaining ring (1).
    • Using a soft-face hammer, tap on the rear output shaft.
  29. Ensure the retaining ring (1) is installed in the groove of the rear output shaft bearing (2).

  30. Object Number: 823222  Size: SH
  31. Install the input shaft in the front case.

  32. Object Number: 823221  Size: SH
  33. Install the viscous coupling on the sun gear.

  34. Object Number: 823220  Size: SH
  35. Install the drive gear on the sun gear.

  36. Object Number: 823243  Size: SH
  37. Using a hammer with the J 45540  (2) and the J 5590  (1), install the bearing on the sun gear. Ensure the bearing is fully seated against the drive gear.

  38. Object Number: 823216  Size: SH
  39. Install the sun gear, with the drive gear and the viscous coupling, on the input gear.

  40. Object Number: 819644  Size: SH
  41. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft using a suitable driver. Install the cup plug 1 mm (0.039 in) from flush with the end of the shaft.

  42. Object Number: 823220  Size: SH

    Important: Ensure to align the marks of the drive chain and sprockets, if using the chain and sprockets again.

  43. Install the drive chain on the drive sprocket.
  44. • The blue link on the chain faces up.
    • Align the chain, if using it again, with the alignment marks made during disassembly.

    Object Number: 823213  Size: SH
  45. Install the driven sprocket and the chain.

  46. Object Number: 823211  Size: SH
  47. Install the front output shaft in the driven sprocket and the bearing.

  48. Object Number: 823207  Size: SH
  49. Lubricate the sun gear thrust washer with J 36850 or equivalent.
  50. Install the sun gear thrust washer.

  51. Object Number: 823206  Size: SH
  52. Install the planetary carrier assembly.

  53. Object Number: 823196  Size: SH
  54. Lubricate the sun gear thrust washer with J 36850 or equivalent.
  55. Install the planetary carrier thrust washer.

  56. Object Number: 823244  Size: SH

    Important: 

       • Ensure that both the sealing surfaces on the front and rear case halves are free of dirt, oil, and cleaning solvent.
       • Ensure the locating pins are installed in the front case half.

  57. Install the locating pins in the front case, if necessary.
  58. Apply a 3.175 mm (1/8 in) bead of room temperature vulcanizing (RTV) sealant GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the mating surfaces of the front case half.

  59. Object Number: 823209  Size: SH
  60. Lower the rear case half into place.

  61. Object Number: 823204  Size: SH
  62. Install the case bolts, the washers, and the brackets.
  63. Tighten
    Tighten the case bolts to 21 N·m (15 lb ft).


    Object Number: 819663  Size: SH
  64. Using the J 45756 , install the rear output shaft seal.

  65. Object Number: 823198  Size: SH
  66. Install the vehicle speed sensor with a NEW O-ring seal.
  67. Tighten
    Tighten the speed sensor to 17 N·m (13 lb ft).


    Object Number: 823193  Size: SH
  68. Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads on the drain plug and fill plug.
  69. Install the drain plug and the fill plug.
  70. Tighten
    Tighten the drain plug and fill plug to 25 N·m (18 lb ft).


    Object Number: 819655  Size: SH
  71. Using the J 43484  (2) and the J 8092  (1), install the front output shaft seal.

  72. Object Number: 823255  Size: SH
  73. Using the J 45758 , install the front input shaft seal.
  74. Remove the transfer case from the J 45759 .