Transfer Case Replacement

Transfer Case Replacement

- Tools Required
- J 44017 Shaft Remover
- SA9133T Slide Hammer

Removal Procedure





1. Raise and support the vehicle.
2. Remove the intermediate drive shaft.


Important: Remove the retainer ring from the stub shaft for tool installation. Discard the used retainer ring.

Important: Use the proper container for fluid loss when the stub shaft is removed. Plug PTU to minimize fluid loss.

3. Disengage the power take-off unit (PTU) stub shaft from the PTU using the J 44017 and SA9133T.





4. Remove the prop-shaft center bearing to underbody bolts.






Important: Index mark the prop-shaft to PTU for re-installation.

5. Remove the front prop-shaft attachment bolts.
6. Compress the CV joint and disengage the prop-shaft from the PTU and secure with wire.





7. Separate the steering gear from the cradle for clearance.





8. Remove the rear powertrain mount bracket bolts from the PTU.





9. Remove the PTU brace bolts and remove the brace.






Notice: To avoid oil loss when removing the PTU, position the assembly only in the upright (in-vehicle) position.

10. Remove the PTU to transmission bolts.
11. Remove the PTU vent hose.

Installation Procedure





Important: Lubricate the seal with transmission fluid prior to PTU installation.

1. Inspect the transmission output shaft seal, replace if damaged.
2. Install the PTU to transmission. Ensure the PTU is fully engaged. Hand start the PTU to transmission bolts. DO NOT tighten.





3. Install the PTU brace. Hand start all 6 bolts.

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Tighten the PTU to transmission bolts.
- Tighten the bolts to 60 Nm (44 ft. lbs.).
5. Tighten the PTU brace bolts.
- Tighten the bolts to 60 Nm (44 ft. lbs.).





6. Hand start all the powertrain mount to PTU bolts and tighten.






Important: Use the index mark for reassembly.

7. Hand start the prop-shaft center bearing bolts.
8. Ensure all the PTU flange and prop-shaft coupling area is clean. Insert coupling into the PTU flange.

Important: Apply Permatex Thread-locker-Blue to bolt threads.

9. Hand start all prop-shaft coupling bolts and tighten.
- Tighten the bolts to 25 Nm (19 ft. lbs.).





10. Install the center bearing bolts.
- Tighten the bolts to 25 Nm (19 ft. lbs.).
11. Install the intermediate drive shaft.
12. Position the steering gear mounts to the cradle.
13. Install the PTU vent hose.





Important: Use sealant GM P/N 12345493 or equivalent on fill plug.

14. Check the PTU fluid fill. Remove the fluid fill plug.
Fill until fluid is just below the bottom of the fill hole.
PTU Fluid: 500 ml (17 oz).
Fill Plug 15 Nm (11 ft. lbs.).
15. Lower the vehicle.
16. Start the engine and observe idle shape. Compare to pre-removal condition, if excessive, perform powertrain balance procedure-operation.
17. Check the transmission oil level and fill as required.