Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Drain the transfer case fluid.
2. Remove the exhaust system.
3. Remove the rear propeller shaft.





4. Support the transmission with a suitable jack and a block of wood.
5. Remove the transmission mount-to-body bolts.





6. Remove the transmission mount-to-transmission bolts.
7. Remove the transmission mount.





8. Install a flat-bladed tool into the notch on the transfer case flange.
9. Using the flat-bladed tool, carefully move the propeller shaft toward the front of the vehicle and remove the propeller shaft from the transfer case flange.





10. Using mechanics wire, tie the front propeller shaft up and out of the way.





11. Using a suitable adjustable jack, support the transfer case.
12. Remove the transfer case bolts.
13. Remove the transfer case.

Installation Procedure

Important: The front propeller shaft must be lines up with the front output shaft at the same time that the input is being slid onto the transmission output shaft and the dowel pins are engaged. The front propeller shaft is too long and can not be installed after the transfer case mounting face is bolted in place to the transmission. The transfer case needs to be loose and slid back slightly so that the cone shape of the constant velocity (CV) joint can be engaged into the front output shaft.





1. Apply grease GM P/N 1051344 (Canadian P/N 993037), or equivalent, on the input splines starting from the front edge to 10 mm inward in a continuous pattern around the inside diameter (ID) of the splines to completely fill the splines.
2. Install the transfer case.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the transfer case-to-transmission bolts.
Tighten the case-to-transmission bolts to 60 Nm (44 ft. lbs.).
4. Remove the support from the transfer case.





5. Untie the front propeller shaft and position to the transfer case.

Important: Ensure that the coned end of the propeller shaft CV joint is installed into the transfer case flange.

6. Install the propeller shaft to the transfer case flange.





7. Inspect the propeller shaft to flange bolts. Replace if damaged or worn.
8. Thoroughly clean the threads using denatured alcohol or equivalent and allow to dry. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the propeller shaft to flange bolts. Ensure that there are no gaps in the threadlock along the length of the filled area of the bolt. Allow the threadlock to cure approximately 10 minutes prior to installation.
9. Install the propeller shaft to transfer case flange bolts. Ensure that the crescent washers are in place on each pair of bolts.
Tighten the bolts in sequence to 30 Nm (22 ft. lbs.).





10. Install the transmission mount.
11. Install the transmission mount-to-transmission bolts.
Tighten the mount-to-transmission bolts 110 Nm (81 ft. lbs.).





12. Install the transmission mount-to-body bolts.
Tighten the mount-to-body bolts to 60 Nm (44 ft. lbs.).
13. Remove the support from the transmission.





14. Install the rear propeller shaft.
15. Install the exhaust system.
16. Refill the transfer case with fluid.