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Transfer Case: Reassembly

  1. Install "C" clip, stop washer, shift fork spring, shift fork and stop washer onto front drive shift shaft. See Fig 1. Secure with "C" clip. Install reduction shift fork onto reduction shift shaft and secure with roll pin. Press bearing onto input gear. Secure with "C" clip.
    Fig 1: Front Drive Shift Shaft Components
    G99B04414Courtesy of GENERAL MOTORS CORP.
  2. Install oil seal into front case. Apply Loctite to oil guide bolt and install with oil guide into rear case. Tighten to specification. See TORQUE SPECIFICATIONS . Press input gear into front case and secure with "C" clip. Press bearings onto front output shaft. Press needle bearing into center case.
  3. Seat oil seal flush with case surface and lubricate seal. Install case gutter into center case. Tighten to specification. See TORQUE SPECIFICATIONS . Using a plastic hammer, drive front output shaft into center case. Press front bearing onto rear output shaft.
  4. Drive output shaft into center case. Apply assembly lube to low output gear needle bearing. Install needle bearing, low output gear and reduction clutch hub onto rear output shaft. Place interlock ball into center case passage and push against interlock notch of front drive shift shaft.
  5. Assemble front drive shift shaft, shift fork, clutch sleeve and clutch hub onto rear output shaft in rear of center case, aligning marks on front drive clutch hub and sleeve. Assemble reduction shift shaft, shift fork and clutch sleeve onto rear output shaft in front of center case, aligning marks on reduction clutch hub and sleeve.
  6. Apply silicone sealer to both rubber plugs. Apply sealant to both locating screws. Install balls, locating springs, rubber plugs, washers and locating screws into center case. Tighten to specification. See TORQUE SPECIFICATIONS . Install NEW countershaft friction ring and "O" ring onto countershaft (if removed).
    NOTE: Friction ring MUST be installed 1.560" (3.95 mm) from end of countershaft. See Fig 2.
    Fig 2: Installing Countershaft Friction Ring
    G99E04415Courtesy of GENERAL MOTORS CORP.
  7. Apply assembly lube to "O" ring and countershaft needle bearings. Install spacer, needle bearings and countergear onto countershaft. Install washer balls and washer onto countershaft. Install countershaft assembly into center case. Apply silicone sealer to front and center case mating surfaces. Assemble case halves and secure with 9 bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
  8. Apply Loctite to countershaft plate bolt. Install countershaft case plate to front case. Tighten to specification. See TORQUE SPECIFICATIONS . Press rear output shaft needle bearing and oil seal into rear case. Install shaft ball on rear output shaft. See Figure. Use a small amount of assembly lube to help keep in place.
  9. Install rear output shaft washer ball, drive sprocket and chain onto front and rear output shaft. Apply assembly lube to drive sprocket needle bearing. Press needle bearing and drive sprocket onto rear output shaft. Press rear bearing onto rear output shaft. Install speedometer drive gear and secure with "C" clip.
  10. Using a straightedge and depth gauge, measure rear case dimension "A" (from mating surface to bottom of bearing bore), plus dimension "B" (straightedge width). See Fig 3. Place straight edge on bearing and measure bearing height "D" (from center case mating surface to bearing top) plus dimension "C" (straightedge width). To prevent false measurements, DO NOT bridge straightedge between bearing and output front shaft bearing. See Fig 3.
  11. Use the formula, CLEARANCE "C" SHIM = A + B - C + D to select correct selective shim to install in bearing bore or rear case. See CLEARANCE "C" SHIM  table.
    CLEARANCE "C" SHIM

    Clearance "C" In. (mm) Shim Size In. (mm)
    0-.005 (0-.13) None
    .005-.009 (.13-.23) .004 (.10)
    .009-.013 (.23-.33) .008 (.20)
    .013-.017 (.33-.43) .012 (.30)
    .017-.021 (.43-.53) .016 (.40)
    .021-.023 (.53-.58) .020 (.50)
  12. Apply assembly lube to selective shim and place on top of rear output shaft rear bearing. Apply silicone sealer to rear case mating surface. Assemble rear case to center case and secure with 15 bolts. Install reduction shift yoke onto shift shaft in rear case and secure with roll pin.
  13. Apply Loctite to select return spring bolt. Install select return pin, ball, washer, spring and spring bolt into rear case. Tighten to specification. See TORQUE SPECIFICATIONS . Apply silicone sealer to gear shift lever housing and secure to rear case with 5 bolts. Tighten to specification.
  14. Install speedometer driven gear case with "O" ring. Install steel balls and 4WD switches into rear case. Tighten to specification.
Fig 3: Measuring Output Shaft Rear Bearing Clearance
G96H30434Courtesy of SUZUKI OF AMERICA CORP.
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