For 1990-2009 cars

## Transfer Case Assemble Borg-Warner 4472

### Assembly Procedure

#### Tools Required

• | J 8092 Universal Driver Handle

• | J 7079-2 Driver Handle

• | J 38212 Needle Bearing Installer

• | J 38423 Output Shaft Roller Needle Bearing Installer

• | J 37668 Seal Installer

• | J 38216 Seal Installer

1. Lubricate all necessary parts with Dextron ™ III Automatic Transmission Fluid or the equivalent.
2. Install the viscous clutch onto the sun gear shaft.
3. Install the drive sprocket onto the sun gear shaft assembly.
4. Install the drive sprocket spacer to the sun gear shaft assembly.
5. Install the sun gear shaft bearing to the sun gear shaft assembly.
6. Use the J 7079-2 and the J 38212 in order to install the input shaft pilot bushing into the output shaft assembly.
7. Install the output shaft assembly to the ring gear.
8. Install the snap ring to the ring gear.
9. Use the J 8092 and the J 38423 in order to install the front output shaft bearing to the front cover.
10. Install the front output shaft bearing snap ring to the front cover.
11. Use the J 7079-2 and the J 38212 in order to install the bearing to the rear case half.
12. Install the output shaft assembly and the ring gear through the rear case half.
13. Install the snap ring to the output shaft bearing
14. Apply a 1/8 inch bead of RTV sealer (GM P/N 12345739) or the equivalent to the rear extension housing sealing surface.
15. Install the rear extension housing.
16. Install the bolts to the rear extension housing.

Tighten
Tighten the bolts to 42 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

17. Lubricate the vehicle speed sensor O-ring with transmission fluid.
18. Install the vehicle speed sensor.
19. Install the speed sensor bolt.

Tighten
Tighten the speed sensor bolt to 16 N·m (12 lb ft).

20. Align the water drain hole in the output shaft oil seal with the drain groove in the extension housing.
21. Use the J 37668 in order to install the output shaft seal.
22. Lubricate the seal sealing lips with automatic transmission fluid.
23. Install the planet carrier thrust washer to the output shaft assembly.

• | Use petroleum jelly in order to lubricate the washer.

• | Align the thrust washer with the input shaft pilot bearing.

24. Install the planet carrier assembly into the ring gear.
25. Install the sun gear thrust washer to the planet carrier assembly.
26. Install the sun gear shaft assembly into the planet carrier assembly gears. Align the viscous clutch teeth with the ring gear spline.
27. Install the input shaft into the input shaft pilot bearing.

• | Align the input shaft with the sun gear shaft thrust washer.

• | Align the input shaft with the planet carrier thrust washer.

28. Install the driven sprocket onto the front output shaft. Install the driven sprocket with the letter E facing down.
29. Install the drive chain onto the driven sprocket and front output shaft.
30. Install the drive chain onto the drive sprocket and install the front output shaft into the output shaft rear bearing.
31. Install the spacer onto the front output shaft.
32. Install the magnet.
33. Apply an 1/8 inch bead of RTV sealer (GM P/N 12345739) or the equivalent to the rear case sealing surfaces.
34. Install the front cover.
35. Install the front cover bolts.

Tighten
Tighten the bolts to 42 N·m (30 lb ft).

36. Use the J 37668 in order to install the front output shaft oil seal.

Lubricate the sealing lips with automatic transmission fluid.

37. Use the J 38216 in order to install the input shaft oil seal.

Lubricate the sealing lips with automatic transmission fluid.

38. Install the front output flange.
39. Install the rubber sealing washer.
40. Install the washer.
41. Install the nut.

Tighten
Tighten the nut to 108 N·m (80 lb ft).