Safari Van AWD V6-262 4.3L VIN Z TBI (1991)
3.
Install the front cover (11) and bolts (9) to the rear case half (10).
^
Tighten front cover bolts (9) to 42 N-m (30 lbs.ft.).
4.
Install the front output flange (5) to the front output shaft (4).
5.
Install the rubber sealing washer (3), steel flat washer (2), and front output flange nut (1).
^
Tighten output flange nut (1) to 108 N-m. (80 lbs. ft.).
INSTALL OR CONNECT TRANSFER CASE TO VEHICLE (Figures 1, 2, 3, and 4)
1.
Make sure all gasket surfaces are clean and free of grease and oil.
2.
Install a new transfer case to adapter gasket (31) (P/N 15642511), if needed.
^
Use gasket sealer to hold gasket in place.
3.
Support transfer case with a jack.
4.
Install the transfer case to transfer case adapter behind the transmission.
5.
Install bolts (35) through the transfer case adapter (30) to the transfer case.
^
Tighten bolts (35) to 52 N-m (38 lbs.ft.).
6.
Remove jack from transfer case.
7.
Install washer's and nuts (38 and 39) to transfer case mount (37) bolts to support brace (17).
^
Tighten nuts (39) to 35 N-m (26 lbs.ft.).
8.
Connect support brace (47), washers (52 and 53)
^
Tighten bolts (53) to 128 N-m (94 lbs.ft.).
9.
Connect electrical connections.
10.
Connect breather hose (16) to vent tube (13).
^
The breather hose must be free of kinks and routed correctly as shown in Figure 9.
11.
Install front and rear propeller shafts. Refer to Section 4A.
12.
Remove filler plug (41) from transfer case.
13.
Fill transfer case with Dextron II E automatic transmission fluid (GM P/N 12345881) until oil level is at the bottom of filler plug hole (1.5 qts., 1.4
liter).
14.
Install fill plug (41).
^
Tighten fill plug (41) to 9 N-m (80 lbs.in.).
15.
Lower the vehicle.
16.
Connect the negative battery cable to the battery. Refer to Section OB.
SERVICE PARTS INFORMATION
Part Number Description Qty
12345997
Sealer
1
15963558
Chain
1
15642511
Gasket
1
Parts are currently available from GMSPO.
