Installation Procedure
INSTALL OR CONNECT1. Raise transfer case into position and slide onto transmission output shaft.
2. Twelve transfer case-to-transmission bolts.
- Tighten Transfer case-to-transmission bolts to 28 Nm (21 ft. lbs.).
3. Breather hose to gearshift lever case; secure with one clamp (if equipped).
4. Breather hose to cover, secure with one clamp (if equipped).
5. Gearshift lever case to rear case manual transmission equipped vehicles. Refer to GEARSHIFT LEVER in MANUAL TRANSMISSION.
6. Raise transfer case slowly until engine is no longer in contact with the wood block between the bulkhead and the distributor gear housing.
7. Remove wood block.
8. Transfer case crossmember to undercarriage; secure with six bolts.
- Transfer case crossmember bolts to 50 Nm (37 ft. lbs.).
9. Two bolts to torque stopper bracket.
- Torque mount bracket bolts to 50 Nm (37 ft. lbs.).
10. Remove hydraulic jack from underneath transfer case.
11. Three Way Catalytic Converter (TWC) and muffler/tail pipe assembly to vehicle.
12. Speedometer cable clip and ground wire to torque stopper housing; secure with one bolt.
- Tighten speedometer cable clip bolt to 10 Nm (89 inch lbs.).
13. Speedometer cable to speedometer driven gear case.
14. Rear propeller shaft into vehicle aligning reference marks made during removal; secure with four bolts and four nuts.
- Tighten rear propeller shaft bolts and nuts to 50 Nm (37 ft. lbs.).
15. Front propeller shaft into vehicle aligning reference marks made during removal; secure with four bolts-and four nuts (if equipped).
- Tighten front propeller shaft bolts and nuts to 50 Nm (37 ft. lbs.).
16. Apply GM P/N 12346004, or equivalent, to the threaded portion of the transfer case drain plug.
17. Transfer case drain plug into transfer case.
- Tighten transfer case drain plug to 28 Nm (21 ft. lbs.).
18. Add approximately 1.7 liters (1.8 qts.) of 75W-90 GL4 lubricant, or equivalent, into the transfer case oil level/filler plug hole. Oil level should be even with the bottom of the oil level filler plug.
19. Apply GM P/N 12346004, or equivalent, to the threaded portion of the transfer case oil level/filler plug.
20. Transfer case oil level/filler plug into transfer case.
- Tighten transfer case oil level/filler plug to 28 Nm (21 ft. lbs.).
21. Transfer case skid plate to transfer case. crossmember; secure with two bolts.
- Tighten transfer case skid plate bolts to 54 Nm (40 ft. lbs.).
22. Lower vehicle.
23. Four bolts to fan shroud at radiator.
- Tighten fan shroud bolts to 10 Nm (89 inch lbs.).
24. Four-wheel drive switch electrical connector to four-wheel drive switch (if equipped).
25. Four-wheel drive low switch electrical connector to four-wheel drive low switch (if equipped).
26. Gearshift control lever into Gearshift lever case and pushing down on the shift control lever pivot and turning clockwise 90° (1/4 turn) and releasing (if equipped).
27. Gearshift lever case boot to gearshift lever case; secure with one clamp (if equipped).
28. Gearshift control lever boot and boot cover onto gearshift control lever; secure with eight screws (if equipped).
29. Gearshift control lever knob onto gearshift control lever; secure with one screw (if equipped).
30. Front console box to floor; secure with two plastic retainers and two screws.
31. Rear console box to floor; secure with two plastic retainers and two screws.
32. Negative (-) battery cable.