Safari Van AWD V6-262 4.3L VIN Z TBI (1991)
3.
Place a drain pan under the transfer case drain plug and remove the drain plug (41).
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Allow oil to drain completely before re-installing the drain plug.
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Tighten the oil drain plug (41) to 9 N-m (80 lbs.in.).
4.
Remove the front and rear propeller shafts. Refer to Section 4A of the appropriate M/L Service Manual.
5.
Disconnect breather vent tube (26) from the top of the transfer case.
6.
Disconnect the electrical plug from the Speed Sensor (7) connection at the transfer case.
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Support transfer case with a jack.
7.
Disconnect the transfer case support brace (47) by removing the bolts and washers (52 and 53) at the transfer case only.
8.
Disconnect and remove the mounting nuts and washers (38 and 39) from the support bracket (17).
9.
Disconnect and remove the adapter to transfer case bolts (35) from the rear of the transfer case adapter.
10.
Remove the transfer case to adapter gasket (31) between the adapter (30) and transfer case (34).
DISASSEMBLY OF THE TRANSFER CASE
Clean the transfer case using solvent and a stiff brush.
REMOVE OR DISCONNECT (Figures 1, 5, 6, 7, and 8)
1.
Remove the front output flange nut (1), steel flat washer (2) and rubber sealing washer (3) from the front output shaft (4).
2.
Remove the front output flange (5) from the front output shaft (4)
3.
Remove the front cover bolts (9) from the rear case half (10).
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The identification tag (40) is an aluminum tag attached under one of the self-tapping case bolts. Every attempt should be made to keep the
identification tag with the unit.
4.
Remove the case half dowel pins (42), quantity of 2, by using a mallet and punch.
5.
Remove the front cover (11) by prying on the tabs (1) provided on the case halves.
6.
Remove the drive chain (13) from the output shaft (4), driven sprocket (14) and the drive sprocket (17).
7.
Remove gasket material thoroughly from the both halves of the transfer case.
CLEANING AND INSPECTION
Clean Make sure the internal gears, sprockets and shafts are clean and free of foreign material.
Inspect
1.
Inspect for excessive wear or damage, spalling, cracks, or corrosion on internal parts of the transfer case.
2.
Inspect case half for damaged or warped mating surfaces, cracks, porosity, or damaged thread holes.
ASSEMBLY OF THE TRANSFER CASE (Figure 5, 6, and 8)
During assembly of the transfer case, lube all necessary parts with Dextron II E Automatic Transmission Fluid or (GM P/N 9985286).
1.
Install the new style drive chain (P/N 15963558) (13) onto the driven sprocket (14) and over the drive sprocket (17).
2.
Apply a 1/8-inch bead of Sealer * (GM P/N 12345997 black sealer) or equivalent to the rear case half (10) front cover sealing surface.
Important
DO NOT USE RTV SEALER (GM P/N 1052366) THAT IS CALLED OUT IN THE M/L SERVICE MANUAL OR UNIT REPAIR MANUAL.
