MODULE REBUILD

83. Install two guide bolts to facilitate installation

of rear output housing 74.
7
4 84. Install a new gasket 73.
3
8
85. Carefully install rear output housing
1 assembly 74 onto the transfer case.
9
10

11 86. Install six bolts 75 and nine bolts 82. Tighten

them to 60–75 N·m (44–55 lb ft) Two bolts
will replace guide bolts.
2
5
87. Install guide bolts in two C6 cover bolt holes.
6
10
88. Install a new gasket 22.
11
89. Position C6 clutch housing assembly 5 on the
transfer case.

90. Install fifteen bolts 23 and two bolts 24.

Tighten them to 60–75 N·m (44–55 lb ft). Two
V07378.04.00 bolts will replace guide bolts.
.

91. Perform selective shim measurement before in-

Figure 5–22. Transfer Case Fitting And Screen
Installation
75. Install fifteen bolts 45 and tighten them to
60–75 N·m (44–55 lb ft). Two bolts will re-
place guide pins.
76. Rotate the assembly so that the rear side is up.
77. Reconnect main wiring harness connector 31
to speed sensor 45 (Foldout 14) and
solenoid 35, making sure that each connector
locks in place.
78. Install a new control cover gasket 42.
79. Install control cover 43.
80. Install ten bolts 44, and tighten them to 24–29 N·m
(18–21 lb ft).
81. If not previously done, remove test fixtures
which were installed during drive and driven
gear bearing preload.
82. Position P4 carrier assembly 56 on the transfer
case.
stalling transfer case into the main transmis-
sion as explained in Paragraph 6–2n.
5–17. CONTROL VALVE MODULE
(Foldout 15)
CAUTION:
• To help prevent transmission damage, protect
control module parts during removal, clean-
ing, inspection, and installation. Keep them in
clean containers until they are installed.
• Control valve module assembly springs and
other parts can be mistakenly interchanged.
Tag each part with its item number as it is re-
moved and use Valve Tray Set J 33163 to sim-
plify correct valve body reassembly.
• Control valve module parts fit together
closely and have specific operating clearances.
They can bind if damaged. These parts de-
pend upon smooth sealing surfaces and may
leak if the sealing surface is scratched. Valves,
when dry, must move freely by their own
weight in their bores. Carefully handle all
such parts.

Copyright © 2005 General Motors Corp. 5–37