Transfer Case Assembly Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft.
4. Remove the vent hose from the transfer case.
5. Disconnect the vehicle speed sensor electrical connectors.
6. Remove the electrical connectors from the transfer case motor/encoder.
7. Remove any wiring harness from the transfer case.
8. Support the transfer case with a transmission jack.
9. Remove the bolt and washer securing the support brace to the transmission.





10. Remove the two bolts securing the support brace to the transfer case.





11. Remove two bolts and washers securing the transfer case adapter to the mount.





12. Remove the six bolts securing the transfer case and bracket to the transmission adaptor.
13. Remove the transfer case.
- Start by pulling the transfer case straight back from the transmission.
- After the transfer case is pulled out from the transmission turn and lower the transfer case.
14. Remove and discard the gasket.


Installation Procedure





1. Install a new gasket to the transmission. Use sealer GM P/N 12346004 in order to hold the gasket in place.
2. Raise and position the transfer case to the vehicle

Notice: Refer to Fastener Notice in Service Precautions.

3. For vehicles equipped with a automatic transmission, install the six bolts securing the transfer case and bracket to the transmission adaptor.
- Tighten the bolts to 47 Nm (35 ft. lbs.).





4. Remove two bolts and washers securing the transfer case adapter to the mount.





5. Install the bolt securing the support brace to the transmission.
- Tighten the bolt to 128 Nm (94 ft. lbs.).





6. Install the two bolts securing the support brace to the transfer case.
- Tighten the bolt and stud to 90 Nm (66 ft. lbs.).





7. Install the vent hose to the transfer case.
8. Check the transfer case oil level. Refer to Oil Replacement.
9. Connect the speed sensor electrical connectors.
10. Install the electrical connectors to the transfer case motor/encoder.
11. Install any wiring harness to the transfer case.
12. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft.
13. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
14. Lower the vehicle.