Express, Savana, G1500, G2500, G3500, 1998-2005

Transfer Case Removal & Installation

Print

  1. Drain transfer case of lubricant.
  2.  
  3. 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 from the transfer case
     
    Transfer case shift linkage
     

  4.  
  5. Support the transfer case with a transmission jack.

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

  6.  
  7. Carefully lower the transfer case.
  8.  

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
     
    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. 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-Express/Savana shown; Avalanche similar

     

  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).
     

  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.  

 
label.common.footer.alt.autozoneLogo