Transfer Case Assembly Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shields. Refer to Shield Replacement.
3. Remove the front propeller shaft. Refer to Propeller Shaft Replacement.
4. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece.
5. Remove the vent hose from the transfer case.
6. Disconnect the vehicle speed sensor electrical connectors.
7. Remove the electrical connectors from the transfer case motor/encoder.
8. Remove any wiring harness from the transfer case.
9. Support the transfer case with a transmission jack.





10. If equipped with a NV3500 manual transmission, remove the bolt securing the left side support brace to the transmission.





11. If equipped with a NV3500 manual transmission, remove the bolt and stud securing the left side support brace to the transfer case.





12. If equipped with a NV3500 manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case.





13. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission.
14. 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.





15. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adaptor.
16. 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.
17. Remove and discard the gasket.


Installation Procedure





1. Install a new gasket to the transmission. Use Teflon Pipe Sealant 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 nuts securing the transfer case and bracket to the transmission adaptor.
Tighten the nuts to 50 Nm (37 ft. lbs.).





4. For vehicles equipped with a manual transmission, install the six nuts securing the transfer case and bracket to the transmission.
Tighten the nuts to 50 Nm (37 ft. lbs.).





5. If equipped with a NV3500 manual transmission, install the bolt securing the left side support brace to the transmission.
Tighten the bolt to 50 Nm (37 ft. lbs.).





6. If equipped with a NV3500 manual transmission, Install the bolt and stud securing the left side support brace to the transfer case.
Tighten the bolt and stud to 50 Nm (37 ft. lbs.).





7. If equipped with a NV3500 manual transmission, install the two bolts securing the right side support brace to the transmission and transfer case.
Tighten the bolts to 50 Nm (37 ft. lbs.).





8. Install the vent hose to the transfer case.
9. Check the transfer case oil level. Refer to Oil Replacement.
10. Connect the speed sensor electrical connectors.
11. Install the electrical connectors to the transfer case motor/encoder.
12. Install any wiring harness to the transfer case.
13. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece.
14. Install the front propeller shaft. Refer to Propeller Shaft Replacement.
15. Install the transfer case shields. Refer to Shield Replacement
16. Lower the vehicle.