Assembly
BEARING AND SEAL REPLACEMENT
Fig. 25 Installing Needle Bearing To Front Drive Sprocket. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 26 Installing Pump Retainer Housing Bearing. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 27 Installing Front Output Seal. New Process Models 231, 233 & 241 Transfer Cases:
Install or Connect
Tools Required:
J 8092 Driver Handle
J 36370 Bearing Installer
J 33833 Bearing Installer
J 36372 Bearing Installer
J 33843 Seal Installer
J 33831 Seal Installer
J 33832 Bearing Installer
^ Use automatic transmission fluid for lubricant during assembly.
Fig. 25 Installing Needle Bearing To Front Drive Sprocket. New Process Models 231, 233 & 241 Transfer Cases:
1. Needle bearings (82) into the drive sprocket (20) using J 36370 and J 8092.
2. Needle bearings (24), into the rear case half (17) using J 33832 and J 8092.
^ Bearing must be flush with the boss on case housing.
3. Bearing (61) into the front case half (45) using J 8092 and J 33833.
4. Retainer (40).
Fig. 26 Installing Pump Retainer Housing Bearing. New Process Models 231, 233 & 241 Transfer Cases:
5. Bearing (6) to the pump retainer housing (8) using J 33833 and J 8092.
6. Bearing (84) into the input gear (38) using J 36372 and J 8092.
7. Thrust washer (37) into planetary carrier (36).
8. Input gear (38) and thrust washer into planetary carrier (36).
9. Carrier lock ring.
10. Bearing into front case half using J 36372.
11. Oil seal (1) into the rear extension (4) using J 33843.
12. Input bearing retainer seal (42) into the input bearing retainer (44) using J 33831.
Fig. 27 Installing Front Output Seal. New Process Models 231, 233 & 241 Transfer Cases:
13. Front output shaft seal (72) into to the front case half (45) using J 33834.
14. Magnet (25) into front case half (45).
INTERNAL COMPONENTS
Fig. 28 Sector W/shaft. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 29 Synchronizer Hub Assembly & Mode Fork. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 30 Oil Pump Pickup Screen Doweled Case Holes. New Process Models 231, 233 & 241 Transfer Cases:
Assemble
1. Synchronizer hub (31) to the synchronizer sleeve (29) along with the three struts (30).
^ Align the previously scribed marks.
2. Spring retainers (32) to the synchronizer hub (31).
3. Main drive synchronizer stop ring (28) to the synchronizer sleeve (29) and the synchronizer hub (31).
4. Drive sprocket (20) to mainshaft (19).
5. Synchronizer assembly to mainshaft (19).
6. Snap ring (83) to mainshaft.
Install or Connect
1. Planetary input gear assembly (38) through the input bearing (40) into the annulus (62) using a soft faced hammer.
2. Bearing retainer (snap ring) (39)to the input gear (38).
3. Input bearing retainer (44) and input bearing retainer bolts (43) to front case half (45).
^ Apply RTV (GM P/N 1052366) on bearing retainer mating surfaces.
^ Apply Loctite 242 or (GM P/N 12345382) to bearing retainer bolts.
Tighten
^ Bolts (43) to 19 N.m (14 ft. lbs).
4. Shift lever 0-ring (67), plastic washer (66), into front case half (45).
Fig. 28 Sector W/shaft. New Process Models 231, 233 & 241 Transfer Cases:
5. Sector with shaft (55) into the front case half (45), shift lever (65), washer (64), and nut (63) to the front case half.
Tighten
^ Nut (63) to 27 N.m (20 ft. lbs).
6. Range shift hub (34) and range shift fork into the front case half (45).
^ It is necessary to rotate the sector to align the range shift fork.
7. Chain over main shaft onto drive gear.
^ Install mainshaft assembly, chain and front output shaft into case as an assembly.
Fig. 29 Synchronizer Hub Assembly & Mode Fork. New Process Models 231, 233 & 241 Transfer Cases:
8. Mainshaft assembly, mode shift fork (54) and rail through range shift fork into front case half (45).
9. Front output shaft (21) into chain front case half (45).
10. Fork shift spring (52) onto the mode shift rail (48).
11. Oil pickup tube (18), oil tube connector (26) and pump pickup screen (35) into the rear case half (17).
12. Oil tube 0-ring (14) onto the oil pump pickup tube (18).
NOTICE: Do not damage the O-ring during assembly as this could result in pump failure.
13. Oil pump (12) to the oil pump pickup tube (18).
^ Apply RTV sealer (GM P/N 1052366) to the case mating surfaces.
14. Rear case (17) over mainshaft (19) and onto the front case half (45).
^ Be careful not to damage the oil pump (12) when installing the case halves together.
Fig. 30 Oil Pump Pickup Screen Doweled Case Holes. New Process Models 231, 233 & 241 Transfer Cases:
15. Case bolts (3) into case halves.
^ Apply Loctite 242 or (GM P/N 12345382) to case bolts.
^ The two longer case bolts and washers into the doweled case holes (33), or from their original holes on transfer cases with attaching brackets.
Tighten
^ Bolts to 31 N.m (23 ft. lbs).
16. Speedometer tone wheel (11) onto mainshaft (19).
17. Pump retainer housing (8) and pump housing bolts (7) to the rear case half (17).
^ Apply Loctite 242 or (GM PIN 12345382) to pump housing bolt threads.
Tighten
^ Bolts to 41 N.m (30 ft. lbs).
18. Output bearing retainer (snap ring) (5) to the main-shaft (19).
19. Rear extension housing (4) and extension housing bolts (3) to the pump retainer housing (8).
^ Apply RTV sealer (GM P/N 1052366) to the extension housing mating surfaces.
^ 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), 0-ring seal (69), and poppet screw (68) into front case half (45).
Tighten
^ Poppet screw to 15 N.m (11 ft. lbs.).
2. Speedometer sensor and O-ring to the pump housing (8).
Tighten
^ Sensor to 31 N.m (23 ft. lbs.).
3. Vacuum switch (46) and 0-ring (47) to the front case housing.
Tighten
^ Switch to 24 N.m (17 ft. lbs.).
4. Front output yoke (74), rubber sealing washer (75), washer (76) and yoke nut (77).
Tighten
^ Front output yoke nut (77) to 149 N.m (110 ft. lbs.).