Assembly

BEARING AND SEAL REPLACEMENT















Install or Connect

Tools Required:

J 8092 Driver Handle
J 36370 Drive Gear Needle Bearing Installer
J 36371 Front and Rear Output Shaft Bearing Installer
J 36372 Input Gear Bearing Installer (Needle bearing)
J 38373 Input Gear Bearing Installer (Ball Bearing)

^ Use automatic transmission fluid where needed in assembly.






1. Needle bearings (82) into the drive sprocket (20) using J 36370 end J 8092.
^ Drive the bearings (82) into the drive sprocket so that they are flush on the synchronizer side.
2. Needle beaning (24) info the rear case half (17) using J 36372 end J 8092.
^ Bearing must be flush with boss on the case housing.









3. Bearing (61) info front case half (45) using J 37371.
4. Bearing retainer (60) into front case hall (45).









5. Bearing (6) into pump retainer housing (8) using J 36371.
6. Bearing (64) to the input gear (38) using J 36372 and J 8082.
7. Thrust washer (37).
8. Carrier locking ring (78).
9. Retainer (87).
10. Bearing (40) to the input gear (38) using J 36373.
11. Retainer ring (snap ring) (41) to the input gear (38).
12. Oil seal (1) to rear extension (4).
13. Input bearing retainer seal (42)10 the input bearing retainer (44).
14. Front output shaft seal (72) to the front case half (45).
15. Magnet (25) to front case half (45).

INTERNAL COMPONENTS


















Assemble

1. Spring retainers (32) to the synchronizer hub (31).
2. Synchronizer hub (31) to he synchronizer sleeve (29) along with the three struts (30).
^ Align the previously scribed marks.
3. Main drive synchronizer stop ring (28) to the synchronizer sleeve (29).

Install or Connect

1. Drive sprocket (20) to the mainshaft (19).
2. Synchronizer assembly (81) to the mainshaft (19).
3. Synchronizer retainer snap ring (83) to the main-shaft (19).
4. Input gear (38) and planetary assembly (36) into the annulus gear (62) using a soft faced hammer.
5. Bearing retainer (snap ring) (39) to the input bearing (40).
6. Input bearing retainer (44) and input bearing retainer bolts (43) to the front case half (45).
^ Apply RTV (GM P/N 1052366) to bearing retainer mating surfaces.
^ Apply Loctite 242 or (GM P/N 12345382) on bearing retainer bolts.

Tighten

^ Bolts (43) to 19 N.m (14 ft. lbs.).

7. Sector with shaft (55) into the front case halt (45).






8. Shift lever O-ring (67), plastic washer (66), shift lever (65), washer (64), and nut (63) to the front case half (45).

Tighten

^ Nut (63) to 27 N.m (20 ft. lbs.).

9. Range shift hub (34) and the range fork into the front case half (45).
^ It is necessary to rotate the sector to align the range shift fork.
10. Front output shaft (21) to the front case half (45).
11. Driven sprocket (22) to the chain (58).
12. Chain (58) onto the drive sprocket (20) located on the mainshaft (19).
^ Mainshaft assembly (19), driver sprocket (22), and chain (58) are installed into the front case half as a unit.
13. Driven gear retainer (snap ring) (23) to front output shaft (21).
14. Mode shift fork (54) onto shift rail (48).
15. Mode shift fork assembly (54) through the range shift fork (52), onto the synchronizer sleeve, and into the front case half (45).
16. Fork shift spring (52) to the shift rail (48).






17. Oil pump pick up tube (18), oil tube connector (26), and pump pick up screen (35) into rear case half (17).
18. Oil tube Oring (14) into oil pump (12).
19. Oil pump (12) to the oil-pick up tube (18).
^ Lubricate oil pump pick tube with automatic transmission fluid before installing into pump.
20. Dowels (33) into front case half.
^ Wipe case mating surfaces clean.
^ Apply RTV sealer (GM P/N 1052366) to case mating surfaces.






21. Rear case half (17) over mainshaft (19) and onto front case half (45).
^ Be careful not to damage the oil pump (12) while installing the rear case half.






22. Case bolts (3) into case halves.
^ Apply Loctite 242 or (GM P/N 12345382) to the case bolts (3).
^ The two longer case bolts and washers into the doweled case holes (33).

Tighten

^ Bolts (3) to 31 N.m (23 ft. lbs.).

23. Retainer (snap ring) (10), speedometer tone wheel (11), and retainer (snap ring) (10) to the mainshaft (19).
24. Pump retainer housing (8) and pump retainer bolts (7) to the rear case half (17).
^ Apply Loctite 242 or (GM P/N 12345382) to pump housing bolts.
^ Pump bolts (7) are shouldered.
25. Output bearing retainer (snap ring) (5) to the main-shaft (19).
26. Rear extension housing (4) and extension bolts (3) to the pump retainer housing (8).
^ Apply RTV (GM P/N 1052366) to the mating surface.
^ Apply Loctite 242 or (GM P/N 12345382) to the extension housing bolts.

Tighten

^ Bolts to 31 N.m (23 ft. lbs.).

EXTERNAL COMPONENTS

Install or Connect

1. Selection plunger (70), poppet spring (71), O-ring seal (69), and poppet screw (68) to the front case half (45).

Tighten

^ Poppet screw to 15 N.m (11 ft. lbs.).

2. Speedometer sensor (9) and O-ring (85) to the pump retainer housing (8).

Tighten

^ Sensor to 31 N.m (23 ft. lbs.).

3. Four wheel drive actuator switch (46) and O-ring (47) to front case half (45).

Tighten

^ Switch to 24 N.m (17 ft. lbs.).

4. Front output flange (74), rubber Sealing washer (75), washer (76), and flange nut (77).

Tighten

^ Nut (26) to 200 N.m (150 ft. lbs.).