GMC T Series 1994 Repair Manual page 851

3.
Mainshaft Extension Bolt
4. Mainshaft Extension
7.
Pump Retainer Housing Bolt
9.
Speedometer Pick-up Switch
15.
Fill/Drain Plug
17.
Rear Case
80.
Identification Tag
Figure 2— Rear View 241—Transfer Case
Important
The annulus gear found in this transfer case is not
serviceable or removable and should only be replaced
as a unit with the front case half. If the annulus gear is
removed, damage to the case will result.
1. Oil pump (12), pickup tube (18), O-ring (14), and
pump pickup filter (35) from the rear case half (17)
(figure 7).
2. Fork shift spring (52).
3. Retainer (snap ring) (23) from the front output shaft
(21).
4. Mainshaft (19), chain (58), and driven sprocket (22)
from the front case half (45) as a unit.
• Mode shift fork (54) and shift rail (48) will be
removed with the mainshaft.
5. Retainer (snap ring) (83) from the mainshaft (19).
6. Synchronizer assembly (81) and drive sprocket
(20) from the mainshaft (19) (figure 5).
7. Range shift fork (51), and range shift hub (34),
from planetary carrier (36).
• It is necessary to rotate the sector with shaft
(55) to obtain clearance when removing the
range fork (51) (figure 6).
8. Shift lever nut (63), washer (64), shift lever (65),
sector and shaft (55), plastic washer (66), and
O-ring (67) from the front case half (45).
9. Input bearing retainer bolts (43) and input bearing
retainer (44) from front case half (45).
10. Retainer ring (snap ring) (41) from input gear (38).
11. Bearing retainer (snap ring) (39).
12. Planetary carrier (36) and input gear (38) from the
annulus gear using a soft faced hammer.
13. Input bearing (40) from the front case half (45)
using J 36370 and J 8092.
A. Snap ring (87)
B. Carrier lock ring (78).
C. Thrust washer (37).
14. Drive sprocket bearings (82) from drive sprocket
(20) using J 29369-1 and J 2619-01 (figure 8).
15. Mainshaft pilot bearing (84) from the input gear
(38) using J 29369-2, J 9276-21, and J 2619-01
(figure 8).
16. Front output bearing retainer (snap ring) (60).
17. Front output shaft seal (72) from front case half
(45).
18. Front output bearing (61) from front case half (45)
using J 33832 and J 8092.
19. Seal (1) from the mainshaft extension housing
20. Seal (42) from input bearing retainer (44).
21. Front output bearing (24) from rear case half (17).
F5385
A. Insert J 29369-2 behind the needle bearings.
B. Using J 2619-01, hammer the bearing from the
case (figure 9).
22. Mainshaft bearing (6) from the oil pump retainer
(8).
23. Magnet (25) from the front case half (45).
❖ Disassemble
• Scribe the location of the synchronizer sleeve and
hub to aid in assembly.
1. Main drive synchronizer stop ring (28) from the
synchronizer sleeve (29).
2. Spring retainers (32) from the synchronizer hub
(31).
3. Synchronizer hub (31) from the synchronizer
sleeve (29).
• Be careful not to damage the synchronizer struts
(30) when removing the sleeve (29) from the hub
(31).
• The oil pump (12) is not serviceable and should be
replaced as a unit only.
(4).