GMC 1989 Light Duty Truck, Repair Manual, Page: 975 / 998

NEW PROCESS 231 TRANSFER CASE 7D3-9
64. W asher
65. S h ift Lever
66. P la s tic W a sh er
67. O -R ing Seal
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Figure 13— Sector with Shaft
11. Drive sprocket (20) and m ainshaft (19) into the chain
(58).
• M ainshaft (19), drive sprocket (20), driven
sprocket (22) and chain (58) are installed as a
unit.
12. Fork shift spring (52) onto the mode shift rail (48).
13. Oil pump pick up tube (18), oil tube connector (26)
and pump pick up screen (35) into the rear case half
(17) (figure 15).
14. Oil tube O-ring (14) onto the oil pump pick up tube
(18).
N O T IC E : Do n o t d a m a g e th e O -rin g d u rin g
assem bly as this c o u ld resu lt in p u m p failure.
15. Oil pump (12) to the oil pump pick up tube (18).
• Apply RTV sealer to the case mating surfaces.
16. Rear case (17) over m ainshaft (19) and onto the front
case half (45).
• Be careful not to damage the oil pump (12)
while installing the rear case half.
17. Case bolts (3) into case halves.
• Apply Loctite 242 or equivalent to case bolts.
Figure 14— Synchronizer Hub Assembly
and Mode Fork
• The two longer case bolts and washers into
doweled case holes (33) (figure 16).
$
T ig h ten
• Bolts to 31 N-m (23 ft. lbs.).
18. Pump retainer housing (8) and pump housing bolts
(7) to the rear case half (17).
• Apply Loctite 242 or equ iva len t on pum p
housing bolt threads.
T ig h ten
• Bolts to 41 N-m (30 ft. lbs.).
19. In p u t b e a rin g re ta in e r (sn a p rin g ) (5) to th e
m ainshaft (19).
20. Retainer (snap ring) (10), speedometer gear (11) and
retainer (snap ring) (10) to the m ainshaft (19).
21. Rear extension housing (4) and extension housing
bolts (3) to the pump retainer housing (8).
• Apply RTV sealer to the mating surfaces.
• A p p ly L o c tite 242 or e q u iv a le n t on th e
extension housing bolts.
^X\
T ig h te n
• Bolts to 31 N-m (23 ft. lbs.).
28. S y n c h ro n iz e r S to p R ing
29. S y n c h ro n iz e r Sleeve
31. S y n c h ro n iz e r H u b
48. S h ift Rail
54. M od e F ork
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