Astro, Safari 1997-2005

Transfer Case Removal & Installation

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  1. Raise the vehicle.
  2.  
  3. Remove engine brace mounting bolts.
  4.  
  5. Remove engine brace.
  6.  
  7. Remove transfer case shield.
  8.  
  9. Remove rear propeller shaft.
  10.  
  11. Remove front propeller shaft.
  12.  
  13. Disconnect motor/encoder electrical connector.
  14.  
  15. Remove transfer case electrical wiring harness.
  16.  
  17. Disconnect transfer case vent hose.
    WARNING
    To perform the following, the transmission mount must be removed for access to the bottom retaining nut of the transfer case. Do not support the transmission by the oil pan.

  18.  
  19. Support the transmission with a suitable transmission jack.
  20.  
  21. Remove transmission mount retaining nuts.
    NOTE
    Raise the transmission assembly enough to clear the rear crossmember.

  22.  
  23. Remove transmission mount bolts and mount assembly.
  24.  
  25. Remove transfer case bottom retaining nut.
    NOTE
    The transmission mount must be replaced in its original position to support the transmission. When reinstalling the transmission mount, it is not necessary reinstall the mounting nuts and bolts. The weight of the transmission and engine will hold the transmission mount in place until this service procedure is completed.

  26.  
  27. Install the transmission mount.
  28.  
  29. Remove the transmission jack stand from the transmission.
  30.  
  31. Remove the transfer case upper retaining nuts.
  32.  
  33. Install the transmission jack to the transfer case.
  34.  
  35. Remove the transfer case assembly.
    WARNING
    DO NOT reuse the old gasket if it is damaged. DO NOT use any type of sealer in place of the gasket.

  36.  
  37. Remove the transfer case gasket.
  38.  

To install:


NOTE
Make sure that the locating tab on the gasket is in the proper location. The locator tab should be facing up.

  1. Install new transfer case gasket.
  2.  
  3. Install transfer case assembly.
  4.  
  5. Install transfer case retaining nuts and tighten them to 40 ft. lbs. (55 Nm).
  6.  
  7. Remove the transmission jack from the transfer case.
  8.  
  9. Position transmission jack to the transmission.
  10.  
  11. Install transmission mount.
  12.  
  13. Install transmission mount bolts and tighten them to 35 ft. lbs. (47 Nm).
  14.  
  15. Lower the transmission into place.
  16.  
  17. Remove the transmission jack stand.
  18.  
  19. Install transmission mount retaining nuts and tighten to 29 ft. lbs. (40 Nm).
  20.  
  21. Connect motor/encoder electrical connector.
  22.  
  23. Install transfer case electrical wiring harness.
  24.  
  25. Connect transfer case vent hose.
  26.  
  27. Install rear propeller shaft.
  28.  
  29. Install front propeller shaft.
  30.  
  31. Install engine brace. Tighten the mounting bolts to 37 ft. lbs. (50 Nm).
  32.  
  33. Inspect the transfer case fluid level.
  34.  
  35. Install the transfer case shield.
  36.  

 
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