3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
The allowable end play is 0.025–0.127 mm
NOTE:
Both idler covers must be installed and tightened to
establish the idler gear position before bearing pre-
load is checked.
35. Install guide pins in two rear idler cover bolt
holes.
36. Install new gasket 47 (Foldout 14) over guide
pins. Install new O-ring 48 on rear idler
cover 49.
37. Lube O-ring and install cover 49 over guide
pins. Install five bolts 50 and tighten them to
60–75 N·m (44–55 lb ft). Two bolts replace the
guide pins.
38. Rotate the transfer case assembly so that the
front side is up.
39. Install guide pins to ease installation of the
front idler cover.
40. Install a new gasket 28 (Foldout 13) over the
guide pins and onto the transfer case.
41. Install shims 25, 26, and 27 (shim pack B) over
the guide pins.
42. Install a new O-ring 24 on cover 23.
43. Lube the O-ring.
44. Install idler cover 23 and tap it lightly with a
soft-faced mallet to seat it in position.
45. Install five bolts 22 and tighten them to 60–75 N·m
(44–55 lb ft). Two bolts replace the guide pins.
46. Remove front idler cover bolts 22, cover 23,
shim pack B, and gasket 28 to start the idler
gear bearing preload check.
47. Install the handle of tool J 39623 into the
threaded hole of idler gear 39.
48. Mount the dial indicator.
49. Bottom the idler gear assembly by slightly ro-
tating tool J 39623 while applying downward
force.
50. Zero the dial indicator.
51. Use a chain hoist and apply 734–778 N
(165–175 lbs) of upward force.
52. Read dial indicator to determine bearing pre-
load.
53. If preload is not within the specified limits, add
or remove shims and repeat Steps (41)–(53).
5–36 Copyright © 2005 General Motors Corp.
(0.001–0.005 inch).
54. When preload is within the specified limits, re-
move the special tools.
55. Install guide pins to ease installation of the
front idler cover.
56. Install a new gasket 28 over the guide pins, and
onto the transfer case.
57. Install shims 25, 26, and 27 (shim pack B).
58. Install a new idler cover O-ring 24.
59. Lube the O-ring.
60. Install idler cover 23, and tap it lightly for in-
stallation.
61. Install five bolts 22 and tighten them to 60–75 N·m
(44–55 lb ft). Two bolts replace the guide pins.
62. Install a new O-ring on main wiring harness
connector 31.
63. Install harness connector assembly 31 on connec-
tor plate 29 and tighten nut 88 to 2.73–4.09 N·m
(24–36 lb in.).
64. Place a new gasket 30 on the connector plate,
carefully rotating wiring harness through the
gasket.
65. Position the harness connector through the
transfer case, and the connector plate.
66. Install four bolts 32 and tighten them to 5–8 N·m
(4–6 lb ft).
67. Install a new O-ring 5 on suction hose fitting 2.
Lube the O-ring (Figure 5–22).
68. Lube the metal boss of filter screen 6 and posi-
tion it in fitting 2.
69. Carefully thread the fitting into the transfer
case.
70. Tighten the jam nut on fitting 2 to 100–120 N·m
(74–89 lb ft).
71. Install C7 clutch assembly 58 (Foldout 13) into
the transfer case.
72. Install guide pins in two front output housing
bolt holes.
73. Install a new output housing gasket 50.
74. Position front output housing 49 on the transfer
case.