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Transfer Case: Reassembly

NOTE: Apply gear oil to all contact surfaces of moving parts and oil seal lips on reassembly.
  1. Install "E" clip, stop washer, shift fork spring, shift fork and stop washer onto front drive shift shaft. See Fig 1 . Install "E" clip securing components on shift shaft. Install reduction shift fork onto reduction shift shaft and secure with roll pin. Using Input Gear Bearing Installer (J-6133-01) and press, install NEW bearing onto input gear. Install input gear bearing snap ring.
  2. Using Oil Seal Installer (J-37752), install NEW input gear oil seal into front case. Apply Loctite to oil guide retaining bolt and install oil guide into rear case. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Using press and appropriate driver, install input gear into front case and secure with "C" clip.
  3. Using Press Tube/Bearing Installer (J-35664), bearing splitter and press, install NEW front output shaft bearings onto front output shaft. Using Needle Bearing Installer (J-37757), install NEW needle bearing into center case. Using Oil Seal Installer (J-37751) and hammer, install NEW front output shaft oil seal flush with center case surface. Coat seal lip with oil. Install both case oil gutters into center case. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Using plastic mallet, install front output shaft into center case.
  4. Using Press Tube/Bearing Installer (J-35664), Bearing Installer (J-37753) and press, install NEW front bearing onto rear output shaft. Apply oil to low output gear needle bearing. Install needle bearing, low output gear, reduction clutch hub and retaining snap ring onto rear output shaft. Using Rear Output Shaft Installer (J-36183) and hammer, install rear output shaft into center case. Apply Transjel (J-36850) to low output gear needle bearing. Place straight edge across top surface of center case. See Fig 2 . Using Bearing Installer (J-37753) and press, install NEW needle bearing into center case until bearing install limit line aligns with bottom edge of straight edge. See Fig 2 .
    Fig 1: Identifying Front Drive Shift Shaft Components
    G99B04414Courtesy of GENERAL MOTORS CORP.
    Fig 2: Installing Low Output Gear Needle Bearing
    G00031505Courtesy of GENERAL MOTORS CORP.
  5. Install reduction hub "C" clip onto rear output shaft. Install caged needle bearing. Place front drive shift shaft in 4WD position and install front drive shift shaft interlock ball into center case passage. See Figure . Install front drive shift fork, front drive clutch sleeve and clutch hub onto rear output shaft in rear of center case, aligning marks on front drive clutch hub and sleeve. Install 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 sealant to both rubber plugs. Apply Loctite thread sealant to both locating screws. Install locating balls, locating springs, washers and locating screws into center case, and tighten to specification. See TORQUE SPECIFICATIONS  . Install rubber plugs on locating screws.
  7. Install NEW countershaft friction ring and "O" ring onto countershaft (if removed). Coat "O" ring and countershaft needle bearings with oil. Install spacer, NEW needle bearings and counter gear onto countershaft. Install washer balls and washer onto countershaft. Install countershaft assembly into center case. Apply silicone sealant to front and center case mating surfaces. Assemble case halves and tighten 9 bolts to specification. See TORQUE SPECIFICATIONS  .
    NOTE: Friction ring MUST be installed 1.560" (3.95 mm) from end of countershaft. See Fig 3 .
    Fig 3: Installing Countershaft Friction Ring
    G99E04415Courtesy of GENERAL MOTORS CORP.
  8. Apply Loctite thread sealant to countershaft case retaining plate bolt. Install countershaft case retaining plate to front case and tighten bolt to specification. See TORQUE SPECIFICATIONS  . Using Needle Bearing Installer (J-37757), install NEW rear output shaft needle bearing into rear case. Using Oil Seal Installer (J-37751) and hammer, install NEW rear output shaft oil seal into rear case. Coat seal lip with oil. Coat shaft ball with Transjel (J-36850) and install shaft ball on rear output shaft. See Figure .
  9. Install rear output shaft washer ball, drive sprocket and drive chain onto front and rear output shaft. Install synchronizer plate to case over front output shaft. Apply Loctite thread sealant to 2 synchronizer plate retaining bolts and tighten. Apply Transjel (J-36850) to drive sprocket needle bearing. Install drive sprocket needle bearing and drive sprocket bushing onto rear output shaft. Using Press Tube/Bearing Installer (J-35664) and press, install NEW rear bearing onto rear output shaft. Install rear bearing retaining "C" clip onto rear output shaft. Install speedometer drive gear onto rear output shaft and secure with "C" clip.
  10. Place straightedge across rear case mounting surface. Measure and record rear case bearing bore depth from top of straightedge to bottom of bearing bore (dimension "A" plus "B"). See Fig 4 . Using Bearing Installer (J-37753) and press, install NEW needle bearing into rear case until bearing installer limit line aligns with bottom surface of straightedge. Using straightedge and depth gauge, measure and record height of rear bearing on rear output shaft, including width of straightedge. Place straight edge on bearing and measure and record bearing height "D" (from case mating surface to top of bearing), and add dimension "C" (straightedge width). See Fig 4 .
  11. Subtract dimensions "C" plus "D" from dimensions "A" plus "B", to find clearance for selection of proper shim thickness. After selecting proper thickness shim, coat shim with Transjel (J-36850) and place on top of rear output shaft rear bearing. For available shims, see CLEARANCE "C" SHIM SELECTION  table.
  12. Apply silicone sealant to rear case mating surface. Assemble rear case to center case and secure with 15 bolts and tighten to 17 ft. lbs. (23 N.m). Install reduction shift yoke onto shift shaft in rear case and secure with roll pin.
  13. Apply Loctite thread sealant to select return spring bolt. Install select return pin, ball, washer, spring and spring bolt into rear case. Tighten bolt to specification. See TORQUE SPECIFICATIONS  . Apply silicone sealant to gearshift lever housing and rear case mating surfaces and install gearshift lever housing to rear case with 5 bolts. Tighten to specification. See TORQUE SPECIFICATIONS  .
  14. Apply Transjel (J-36850) to speedometer driven gear case "O" ring, and install speedometer driven gear in transfer case. Install steel balls and 4WD switches into rear case. Tighten all fasteners and components to specification. See TORQUE SPECIFICATIONS  .
CLEARANCE "C" SHIM SELECTION

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)
Fig 4: Measuring Output Shaft Rear Bearing Clearance
G96H30434Courtesy of SUZUKI OF AMERICA CORP.
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