Transfer Case Assemble

Single Use Fasteners and Components Transfer Case Access Hole Plug Transfer Case Four Wheel Drive Clutch Housing Retaining Ring Transfer Case Front Output Shaft Boot Transfer Case Front Output Shaft Boot Clamp Transfer Case Front Output Shaft Drive Sprocket Retaining Ring Transfer Case Input Shaft Bearing Outer Retaining Ring Transfer Case Input Shaft Bearing Retaining Ring Transfer Case Rear Output Shaft Rear Bearing Retaining Ring Transfer Case Rear Output Shaft Seal Transfer Case Two/Four Wheel Drive Actuator Position Sensor Gasket Transfer Case Two/Four Wheel Drive Clutch Retaining Ring Transfer Case Vent Special Tools DT-42738 Seal Installer DT-45759 Assembly Fixture DT-48213 Clutch Pack Height Gauge DT-50648–A Seal Installer DT-51204 Case Separating Tool J-44636-1 Front Output Shaft Seal Protector J-44636-2 Front Output Shaft Seal Installer GE-3289-20 Holding Fixture Equivalent regional tools: Special Tools

Transfer Case Assemble — figure 1

1. Transfer Case Input Shaft Bearing (1) » Install
2. Transfer Case Input Shaft Bearing Outer Retaining Ring (2) » Install NEW
3. Transfer Case High/Low Planetary Carrier (3) » Install
4. Transfer Case High/Low Planetary Carrier Pinion Gear Thrust Washer (4) » Install
5. Transfer Case Input Shaft (5) » Install
6. Transfer Case High/Low Planetary Carrier Pinion Gear Thrust Washer (6) » Install
7. Transfer Case High/Low Locking Plate (7) » Install NEW
8. Transfer Case Input Shaft Bearing Retaining Ring (8) » Install
9. Transfer Case Input Shaft/Planetary Assembly (9) » Install
10. Transfer Case Input Shaft Bearing Outer Retaining Ring (10) » Install NEW

Transfer Case Assemble — figure 2

11. The DT-48213 Clutch Pack Height Gauge (3) applies a predetermined amount of pressure to the clutch pack in order to properly measure the clutch pack height. Do not use any other method than what is outlined below.
12. Micrometers or depth gauges may also be used in conjunction with the DT-48213 Clutch Pack Height Gauge (3) to measure the clutch pack height.
13. Two variations are available to measure clutch pack height, outside measurement or inside measurement. Either variation will determine the correct height.
14. Transfer Case Four Wheel Drive Clutch Pressure Plate – Friction(1) » Install [8x] 14.1. Install the friction and steel clutch plates into the DT-48213 Clutch Pack Height Gauge (3), alternating until 8 friction plates and 7 steel plates are installed.
15. Transfer Case Four Wheel Drive Clutch Pressure Plate – Steel (1) » Install [7x] 15.1. Tighten the DT-48213 Clutch Pack Height Gauge (3) until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates. 15.2. Using an outside caliper, measure the total combined height of the clutch pack and the DT- 48213 Clutch Pack Height Gauge (3), dimension (a). Subtract the thickness of both the upper and lower portion of the DT-48213 Clutch Pack Height Gauge (3), 14 mm (0.551 in), and record the results. 15.3. Repeat the process in 2 additional locations, 120 degrees from each other. 15.4. The average of the 3 measurements is the clutch pack height. 15.5. Install the friction and steel clutch plates into the DT-48213 Clutch Pack Height Gauge (3), alternating until 8 friction plates and 7 steel plates are installed. 15.6. Tighten the DT-48213 Clutch Pack Height Gauge (3) until the upper portion of the tool contacts the lower portion of the tool. The screw will be flush with the bottom surface of the tool to indicate the tool has fully compressed the clutch plates. 15.7. Using an inside caliper, measure the height of the clutch pack, dimension (b), and record the results. 15.8. Repeat the process in 2 additional locations, 120 degrees from each other. 15.9. The average of the 3 measurements is the clutch pack height.

Transfer Case Assemble — figure 3

16. Transfer Case Control Actuator Thrust Bearing (5) » Install
17. Transfer Case Control Actuator Lever Bearing Assembly (4) » Install
18. Transfer Case Scissor Mechanism Lever (3) » Install
19. Transfer Case Scissor Lever Ball (2) » Install [3x]
20. Transfer Case Scissor Mechanism Lever (1) » Install

Transfer Case Assemble — figure 4

21. Transfer Case Control Actuator Lever Bearing (4) » Install
22. Transfer Case Control Actuator Lever Washer (3) » Install

Note

Ensure the control actuator lever washer is seated into the apply plate groove.

23. Transfer Case Four Wheel Drive Clutch Pressure Plate – Apply(2) » Install
24. Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (1) » Install [4x]

Transfer Case Assemble — figure 5

Note

Alternate between the friction and steel plates until there are 8 friction plates and 7 steel plates installed.

25. Transfer Case Four Wheel Drive Clutch Pressure Plate – Friction (2) » Install [8x]
26. Transfer Case Four Wheel Drive Clutch Pressure Plate – Steel (3) » Install [7x]
27. Transfer Case Four Wheel Drive Clutch Hub (1) » Install

Transfer Case Assemble — figure 6

Note

A variety of shims are available to properly adjust the clearance height of the clutch assembly. An inside micrometer may also be used to measure the clutch assembly height.

28. Using an inside caliper, measure the height of the clutch assembly in the location (a) shown and record the results.
29. Repeat the process in 2 additional locations, 120 degrees from each other.
30. The average of the 3 measurements is the clutch assembly height.
31. A 3.1 mm (0.122 in) clearance +/− 0.1 mm (0.004 in) is necessary between the clutch pack height and the assembly height. It may be necessary to replace the clutch shim with a thicker shim or a thinner shim, to achieve the proper clearance in the clutch.
32. Subtract the clutch pack height from the clutch assembly height. The difference should be between 3.0 mm (0.118 in) and 3.2 mm (0.126 in) clearance.

Transfer Case Assemble — figure 7

33. Transfer Case Four Wheel Drive Clutch Shim (4) » Install
34. Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (3) » Install NEW
35. Transfer Case Front Output Shaft Driven Sprocket Spacer - Front (2) » Install
36. Transfer Case Four Wheel Drive Clutch Housing (1) » Install

Transfer Case Assemble — figure 8

37. Transfer Case Four Wheel Drive Clutch Housing Retaining Ring (5) » Install NEW
38. Transfer Case Front Output Shaft Drive Sprocket (4) » Install
39. Transfer Case Front Output Shaft Driven Sprocket Spacer - Rear (3) » Install

Note

Ensure the retaining ring is installed into the correct retaining ring groove on the rear output shaft.

40. Transfer Case Front Output Shaft Drive Sprocket Retaining Ring (2) » Install
41. Transfer Case Oil Pump (1) » Install

Transfer Case Assemble — figure 9

42. Transfer Case Rear Output Shaft Bearing Spacer (3) » Install
43. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) » Install NEW
44. Transfer Case Rear Output Shaft Rear Bearing (2) » Install 44.1. Use an arbor press or suitable installer to install the bearing to the rear output shaft. 44.2. Ensure the retaining ring groove in the outer race is positioned toward the rear.
45. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) » Install NEW

Transfer Case Assemble — figure 10

Note

Load all 3 components simultaneously.

46. Transfer Case High/Low Shift Fork Assembly (1) » Install
47. Transfer Case High/Low Clutch (2) » Install
48. Transfer Case Rear Output Shaft Assembly (3) » Install

Transfer Case Assemble — figure 11

49. Transfer Case Front Output Shaft Drive Chain Assembly (1) » Install 49.1. Install the chain with darkened links up. 49.2. Install the front output shaft assembly into the front case half while engaging the chain with the drive sprocket.
50. Transfer Case Front Output Shaft (2) » Install
51. Install the transfer case actuator shaft gear (3).
52. Transfer Case Oil Pump Suction Pipe Seal (4) » Install NEW 52.1. Lubricate the seal to ease installation. 52.2. Install the seal to the pipe prior to inserting the pipe into the pump.
53. Transfer Case Oil Pump Suction Pipe (5) » Install

Transfer Case Assemble — figure 12

54. Transfer Case Front Case Half (1) » Install

Caution

Apply the proper amount of sealant to the transfer case (front half) sealing surface when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure. 54.1. Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent. 54.2. Apply a 2 mm (0.078 in) bead of sealant to the front case half. Adhesives, Fluids, Lubricants, and Sealers

55. Transfer Case Rear Case Half (2) » Install 55.1. Ensure the transfer case rear output shaft outer retaining ring is in place and aligned prior to mating case halves. 55.2. Use snap ring pliers to open the transfer case rear output shaft outer retaining ring for the transfer case rear output shaft rear bearing assembly. 55.3. Ensure snap ring is sitting properly by rotating the entire transfer case and then let gravity seat the snap ring. Listen for a definite click sound.
56. Transfer Case Bracket (3) » » Install

Caution

Refer to Fastener Caution.

Note

Do not use power tools.

57. Transfer Case Half Bolt (4) » Install NEW and tighten [17x] — Fastener Specifications

Transfer Case Assemble — figure 13

Note

Align the notch on the seal between the rear output bearing retaining ring access holes, this will position the weep hole down.

58. Using the DT-48210 Seal Installer  (2) and J-8092 Driver Handle  (3) install a NEW transfer case rear output shaft seal (1).

Transfer Case Assemble — figure 14

Note

Apply retaining compound to the vent pipe before installation. Adhesives, Fluids, Lubricants, and Sealers

59. Transfer Case Vent (1) » Install NEW

Note

Apply pipe sealant to the oil fill plug before installation. Adhesives, Fluids, Lubricants, and Sealers

60. Transfer Case Access Hole Plug (2) » Install NEW [2x]

Note

Apply pipe sealant to the oil drain plug before installation. Adhesives, Fluids, Lubricants, and Sealers

61. Transfer Case Oil Fill Plug (3) » Install — Fastener Specifications
62. Transfer Case Oil Drain Plug (4) » Install — Fastener Specifications

Caution

Refer to Component Fastener Tightening Caution.

Transfer Case Assemble — figure 15

Note

Lightly lubricate the O-ring with clean DEXRON®VI.

63. Transfer Case Two/Four Wheel Drive Actuator Position Sensor Gasket (1) » Install NEW
64. Transfer Case Two/Four Wheel Drive Actuator Position Sensor (2) » Install
65. Transfer Case Two/Four Wheel Drive Actuator Position Sensor Bolt (3) » Install [2x] — Fastener Specifications

Transfer Case Assemble — figure 16

66. Transfer Case Two/Four Wheel Drive Actuator (1) » Install
67. Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw (2) » Install and tighten [4x] — Fastener Specifications

Transfer Case Assemble — figure 17

Note

Ensure the bore of the front case half is free of dirt, oil, and cleaning solvent. This application uses a single lip input shaft oil seal with a DRY adapter cavity and it is to be installed with the spring portion of the seal facing inward towards the internals of the transfer case.

68. Install a NEW transfer case input shaft seal (1) using the DT-42738 Seal Installer (2).
69. Install a NEW transfer case front output shaft seal (4) using the DT-50648–A Seal Installer (3)

Transfer Case Assemble — figure 18

70. Use J-44636-2 Front Output Shaft Seal Installer (5) to install the transfer case front output shaft oil slinger (1).
71. Transfer Case Front Output Shaft Boot Clamp (2) » Install NEW
72. Transfer Case Front Output Shaft Boot (3) » Install NEW
73. Transfer Case Front Output Shaft Boot Clamp (2) » Install NEW

Transfer Case Assemble — figure 19

74. Transfer Case Nut (3) » Remove [6x]

Note

The Transfer Case Range Actuator Learn must be preformed after the transfer case is installed in the vehicle.

75. Remove the transfer case (4) from the GE-3289-20 Holding Fixture (1) and DT-45759 Assembly Fixture (5).