Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

Transfer Case Removal & Installation

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  1. Remove or disconnect the following:

    Transfer case shields
     
    Front propeller shaft
     
    Rear propeller shaft
     
    Shift rod from the transfer case
     
    Vent hose from the transfer case
     
    Vehicle Speed Sensor (VSS) electrical connectors
     
    All necessary wiring harnesses from the transfer case
     

  2.  
  3. Support the transfer case with a transmission jack.
  4.  
  5. If equipped with a NV3500 manual transmission, remove or disconnect the following:

    Bolt securing the left side support brace to the transmission
     
    Bolt and stud securing the left side support brace to the transfer case
     
    Two bolts securing the right side support brace to the transmission and transfer case
     

  6.  
  7. Remove or disconnect the following:

    Six nuts securing the transfer case and bracket to the transmission or transmission adapter, as applicable
     
    Transfer case
     
    Gasket, then discard
     

  8.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle.
  4.  
  5. Install or connect the following:

    Six nuts securing the transfer case and bracket to the transmission adapter or transmission. Tighten to 37 ft. lbs. (50 Nm).
     

  6.  
  7. If equipped with a manual transmission, install or connect the following:

    Bolt securing the left side support brace to the transmission and tighten to 37 ft. lbs. (50 Nm)
     
    Bolt and stud securing the left side support brace to the transfer case and tighten to 37 ft. lbs. (50 Nm)
     
    Two bolts securing the right side support brace to the transmission and transfer case and tighten to 37 ft. lbs. (50 Nm)
     

  8.  
  9. Install or connect the following:

    Vent hose to the transfer case
     

  10.  
  11. Check the transfer case oil level.

    VSS electrical connectors
     
    Wiring harness to the transfer case
     
    Shift rod to the transfer case
     
    Front and rear propeller shafts
     
    Transfer case shields
     

  12.  
  13. Lower the vehicle.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain transfer case of lubricant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate, if equipped
     
    Vent hose clamp at the transfer case
     
    Front driveshaft at the transfer case and support it aside
     
    Rear driveshaft and support it aside
     
    Electrical connections at the transfer case
     
    Transfer case shift linkage
     

  6.  
  7. Support the transfer case with a transmission jack.

    Transmission to transfer case bolts and spring washers
     
    Transfer case assembly and gasket
     

  8.  
  9. Carefully lower the transfer case.
  10.  

To install:

  1. Carefully raise the transfer case into position.
  2.  
  3. Install or connect the following:

    New gasket to the transmission using gasket sealer to hold it in place
     
    Transfer case onto the transmission or transmission adapter. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Electrical harness connectors to the transfer case connections
     
    Transfer case shift linkage and make the proper adjustments
     
    Front and rear driveshafts
     

  4.  
  5. Refill the transfer case with DEXRON®IIE automatic transmission fluid.

    Skid plate, if equipped
     
    Negative battery cable
     

  6.  
  7. Test drive for proper operation.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain transfer case of lubricant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Skid plate, if equipped
     
    Vent hose clamp at the transfer case
     
    Front driveshaft at the transfer case and support it aside
     
    Rear driveshaft and support it aside
     
    Electrical connections at the transfer case
     
    Transfer case shift linkage
     

  6.  
  7. Support the transfer case with a transmission jack.

    Transmission to transfer case bolts and spring washers
     
    Transfer case assembly and gasket
     

  8.  
  9. Carefully lower the transfer case.
  10.  

To install:

  1. Carefully raise the transfer case into position.
  2.  
  3. Install or connect the following:

    New gasket to the transmission using gasket sealer to hold it in place
     
    Transfer case onto the transmission or transmission adapter. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Electrical harness connectors to the transfer case connections
     
    Transfer case shift linkage and make the proper adjustments
     
    Front and rear driveshafts
     

  4.  
  5. Refill the transfer case with DEXRON®IIE automatic transmission fluid.

    Skid plate, if equipped
     
    Negative battery cable
     

  6.  
  7. Test drive for proper operation.
  8.  

  1. Remove or disconnect the following:

    Transfer case shields
     
    Front propeller shaft
     
    Rear propeller shaft
     
    Shift rod from the transfer case, if equipped
     
    Vent hose from the transfer case
     
    Vehicle Speed Sensor (VSS) electrical connectors
     
    All necessary wiring harnesses from the transfer case
     
    Crossmember, if equipped
     

  2.  
  3. Support the transfer case with a transmission jack.
  4.  
  5. Remove or disconnect the following:

    Six nuts securing the transfer case and bracket to the transmission or transmission adapter, as applicable
     
    Transfer case
     
    Gasket, then discard

    Click image to see an enlarged view

    Fig. Transfer case mounting nuts (1), transfer case (2) and transfer case gasket (3)

     

  6.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle.
  4.  
  5. Install or connect the following:

    Six nuts securing the transfer case and bracket to the transmission adapter or transmission. Tighten to 37 ft. lbs. (50 Nm)
     
    Crossmember, if equipped. Tighten the bolts to 52 ft. lbs. (70 Nm)
     
    Vent hose to the transfer case
     

  6.  
  7. Check the transfer case oil level.

    VSS electrical connectors
     
    Wiring harness to the transfer case
     
    Shift rod to the transfer case, if equipped
     
    Front and rear propeller shafts
     
    Transfer case shields
     

  8.  
  9. Lower the vehicle.
  10.  

Borg-Warner 4481-Nr3 & 4482-Nr4



  1. Raise and support the vehicle.
  2.  
  3. Remove the transfer case shield, if equipped.
  4.  
  5. Remove the front and rear driveshafts.
  6.  
  7. Drain the fluid from the transfer case.
  8.  
  9. Disconnect the speed sensor electrical connector.
  10.  
  11. Remove the clip from the transfer case bracket.
  12.  
  13. Reposition the speed sensor wire.
  14.  
  15. Remove the clips from the fuel pipe bracket.
  16.  
  17. Remove the fuel pipe clip from the fuel pipe bracket.
  18.  
  19. Remove the transmission mount nuts.
  20.  
  21. Remove the crossmember bolts.
  22.  
  23. Remove the crossmember.
  24.  
  25. Install a suitable transmission jack to the transfer case.
  26.  
  27. Remove the transfer case adapter nuts.
  28.  
  29. Remove the fuel pipe bracket from the studs.
  30.  
  31. Remove the transfer case from the adapter.
  32.  
  33. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
  34.  
  35. Lower the transfer case.
  36.  
  37. Remove the gasket from the transfer case.
  38.  
  39. Remove the transfer case from the transmission jack.
  40.  

To install:

  1. Install the transfer case onto a suitable transmission jack.
  2.  
  3. When installing a new transfer case gasket, the gasket must be installed with the tab oriented up, and the yellow printing toward the front of the vehicle. Install the gasket without the use of any type of sealant or of lubricant.
  4.  
  5. Install a new transfer case gasket.
  6.  
  7. Rotate the transfer case so that it is parallel to the torsion bar mounting bracket.
  8.  
  9. Raise the transfer case into position.
  10.  
  11. Rotate the transfer case so that it is aligned with the adapter.
  12.  
  13. Install the transfer case to the adapter.
  14.  
  15. Install the fuel pipe bracket onto the studs.
  16.  
  17. Install the transfer case adapter nuts and tighten to 37 ft. lbs. (50 Nm).
  18.  
  19. Position the crossmember.
  20.  
  21. Install the crossmember bolts and tighten to 52 ft. lbs. (70 Nm).
  22.  
  23. Install the transmission mount nuts and tighten to 30 ft. lbs. (40 Nm).
  24.  
  25. Remove tool Jack stand from the transmission.
  26.  
  27. Install the fuel pipe clip to the fuel pipe bracket.
  28.  
  29. Install the clips to the fuel pipe bracket.
  30.  
  31. Position the speed sensor wire.
  32.  
  33. Install the clip to the transfer case bracket.
  34.  
  35. Connect the speed sensor electrical connector.
  36.  
  37. Install the driveshafts
  38.  
  39. Fill the transfer case with fluid.
  40.  
  41. Install the transfer case shield, if equipped.
  42.  

Nvg246-Np8



  1. Remove or disconnect the following:

    Transfer case shields
     
    Front driveshaft
     
    Rear driveshaft
     
    Vent hose from the transfer case
     
    Vehicle speed sensor electrical connectors
     
    Electrical connectors from the transfer case motor/encoder
     
    Any wiring harness from the transfer case
     

  2.  
  3. Support the transfer case with a transmission jack.
  4.  
  5. Remove the six nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case.
  6.  
  7. Remove and discard the gasket.
  8.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle
  4.  
  5. Install the six nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install or connect the following:

    Vent hose to the transfer case
     
    Oil
     
    Speed sensor electrical connectors
     
    Electrical connectors to the transfer case motor/encoder
     
    Any wiring harness to the transfer case
     
    Rear driveshaft
     
    Front driveshaft
     
    Transfer case shields
     

  8.  

NVG246-NP8 2-Speed Automatic



  1. Remove or disconnect the following:

    Transfer case shields
     
    Front propeller shaft
     
    Rear propeller shaft
     
    Vent hose from the transfer case
     
    Vehicle speed sensor electrical connectors
     
    Electrical connectors from the transfer case motor/encoder
     
    Any wiring harness from the transfer case
     

  2.  
  3. Support the transfer case with a transmission jack.
  4.  
  5. If equipped with a NV3500 manual transmission, remove the bolt securing the left side support brace to the transmission.
  6.  
  7. If equipped with a NV3500 manual transmission, remove the bolt and stud securing the left side support brace to the transfer case.
  8.  
  9. If equipped with a NV3500 manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case.
  10.  
  11. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission. Remove the transfer case.
  12.  
  13. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case.
  14.  
  15. Remove and discard the gasket.
  16.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle
  4.  
  5. For vehicles equipped with a automatic transmission, install the six nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 50 Nm (37 ft. lbs.).
  6.  
  7. 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.).
  8.  
  9. 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.).
  10.  
  11. 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.).
  12.  
  13. 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.).
  14.  
  15. Install or connect the following:

    Vent hose to the transfer case
     
    Oil
     
    Speed sensor electrical connectors
     
    Electrical connectors to the transfer case motor/encoder
     
    Any wiring harness to the transfer case
     
    Rear propeller shaft
     
    Front propeller shaft
     
    Transfer case shields
     

  16.  

NVG261-NP2 2-Speed Manual



  1. Remove or disconnect the following:

    Transfer case shields
     
    Front driveshaft
     
    Rear driveshaft
     
    Shift rod from the transfer case
     
    Vent hose from the transfer case
     
    Vehicle speed sensor electrical connectors
     
    Any wiring harness from the transfer case
     

  2.  
  3. Support the transfer case with a transmission jack.
  4.  
  5. Remove the 6 nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case.
  6.  
  7. Remove and discard the gasket.
  8.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle
  4.  
  5. Install the 6 nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install or connect the following:

    Vent hose to the transfer case
     

  8.  
  9. Check the transfer case oil level.

    Speed sensor electrical connectors
     
    Wiring harness to the transfer case
     
    Shift rod to the transfer case
     
    Rear driveshaft
     
    Front driveshaft
     
    Transfer case shields
     

  10.  
  11. Lower the vehicle.
  12.  

  1. Remove or disconnect the following:

    Transfer case shields
     
    Front propeller shaft
     
    Rear propeller shaft
     
    Shift rod from the transfer case
     
    Vent hose from the transfer case
     
    Vehicle speed sensor electrical connectors
     
    Any wiring harness from the transfer case
     
    Support the transfer case with a transmission jack.
     

  2.  
  3. If equipped with a NV3500 manual transmission, remove the bolt securing the left side support brace to the transmission.
  4.  
  5. If equipped with a NV3500 manual transmission, remove the bolt and stud securing the left side support brace to the transfer case.
  6.  
  7. If equipped with a NV3500 manual transmission, remove the 2 bolts securing the right side support brace to the transmission and transfer case.
  8.  
  9. For vehicles equipped with a manual transmission, remove the 6 nuts securing the transfer case and bracket to the transmission. Remove the transfer case.
  10.  
  11. For vehicles equipped with a automatic transmission, remove the 6 nuts securing the transfer case and bracket to the transmission adapter. Remove the transfer case.
  12.  
  13. Remove and discard the gasket.
  14.  

To install:

  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.  
  3. Raise and position the transfer case to the vehicle
  4.  
  5. For vehicles equipped with a automatic transmission, install the 6 nuts securing the transfer case and bracket to the transmission adapter. Tighten the nuts to 50 Nm (37 ft. lbs.).
  6.  
  7. For vehicles equipped with a manual transmission, install the 6 nuts securing the transfer case and bracket to the transmission. Tighten the nuts to 50 Nm (37 ft. lbs.).
  8.  
  9. If equipped with a NVG 261manual transmission, install the bolt securing the left side support brace to the transmission. Tighten the bolt to 50 Nm (37 ft. lbs.).
  10.  
  11. If equipped with a NVG 261 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.).
  12.  
  13. If equipped with a NVG 261manual transmission, install the 2 bolts securing the right side support brace to the transmission and transfer case. Tighten the bolts to 50 Nm (37 ft. lbs.).
  14.  
  15. Install the vent hose to the transfer case.
  16.  
  17. Check the transfer case oil level.
  18.  
  19. Connect the speed sensor electrical connectors.
  20.  
  21. Connect wiring harness to the transfer case.
  22.  
  23. Install the shift rod to the transfer case.
  24.  
  25. Install the rear propeller shaft.
  26.  
  27. Install the front propeller shaft.
  28.  
  29. Install the transfer case shields.
  30.  
  31. Lower the vehicle.
  32.  

 
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