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    GM Astro/Safari 1985-1996 Repair Guide

    Transfer Case Assembly

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    REMOVAL & INSTALLATION



    See Figure 1

    The manufacturer recommends that you drain the transmission fluid before attempting to remove the transfer case assembly from the vehicle. The major reason for this is that depending on the condition of the case's seals and how the case assembly is manipulated during removal, there is a chance that the fluid will spill causing quite a mess. Even if the seals are in good condition, with the driveshafts removed, fluid will be able leak past them readily. The vent hose is another possible escape route. The bottom line is that you will have to make up your own mind.

    If you decide to drain the fluid from a transfer case that you are also planning on returning to service, it may be a good idea to drive the vehicle and thoroughly warm the fluid before draining. This will assure you the best fluid change possible.

    1. Disconnect the negative battery cable for safety.
    2.  
    3. Raise and support the vehicle safely using jackstands.
    4.  
    5. Drain the oil from the transfer case into a suitable container.
    6.  
    7. Matchmark and remove the driveshafts.
    8.  
    9. If necessary, disconnect the breather hose.
    10.  
    11. Disengage all electrical connectors.
    12.  
    13. Support the transfer case with a suitable jack.
    14.  
    15. Remove the transfer case support bracket and adapter-to-case bolts.
    16.  
    17. Remove the transfer case mount nuts and washers, then carefully lower the transfer case from the vehicle.
    18.  
    19. Remove and discard the old adapter gasket.
    20.  

    To install:
    1. Make sure all gasket surfaces are clean and free of grease or oil.
    2.  
    3. Install a new transfer case-to-adapter gasket with sealer.
    4.  
    5. Carefully raise the transfer case assembly into position and Install the transfer case-to-adapter bolts. Tighten the bolts to 38 ft. lbs. (52 Nm).
    6.  
    7. Remove the jack from the case assembly.
    8.  
    9. Install the case mount to the crossmember using the washers and nuts. Tighten the retaining nuts to 26 ft. lbs. (35 Nm).
    10.  
    11. Install the support bracket to the engine and/or transfer case, depending on which bolts were removed. Tighten the bracket-to-engine bolts to 94 ft. lbs. (128 Nm) and/or the bracket-to-transfer case bolts to 66 ft. lbs. (90 Nm).
    12.  
    13. Engage the electrical connectors and, if removed, connect the breather hose.
    14.  
    15. Align and install the front and rear driveshafts.
    16.  
    17. Check the transfer case lubricant by removing the fill plug (but remember that if the vehicle MUST be level so you may have to raise and support the other end as well, unless there is sufficient clearance with the vehicle completely lowered. If fluid does not spill out of the hole, add automatic transmission fluid (Dexron®III or Dexron®II, please refer to General Information & Maintenance for more details) to the fill hole until lubricant reaches the top of the hole.
    18.  
    19. Remove the jackstands and carefully lower the vehicle.
    20.  
    21. Connect the negative battery cable and check operation.
    22.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the transfer case assembly mounting

     
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