GM Blazer/Jimmy/Typhoon/Bravada 1983-1993 Repair Guide

Transfer Case

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FLUID RECOMMENDATIONS



When adding fluid or refilling the transfer case, use Dexron® II automatic transmission fluid for most vehicles covered by this repair guide. However, there are indications that some models may have been designed to run with SAE 80W or SAE80W-90 GL5, so check your owners manual to be sure.

LEVEL CHECK



See Figure 1

When checking the fluid, the vehicle must be level. If it was necessary to raise and support the vehicle to access the filler plug, the vehicle must be supported at sufficient points (all wheels or 4 points on the frame) so it is sitting level and is not tilted forward/backward or to one side.



Click image to see an enlarged view

Fig. Fig. 1: Check the fluid level by removing the upper of the 2 plugs from the side of the transfer case

  1. If necessary for access to the filler plug, raise and support the vehicle safely using jackstands, but make sure the vehicle is level.
  2.  
  3. Remove the filler plug (upper plug of 2) from the rear-side of the transfer case.
  4.  
  5. Using your finger, check the fluid level, it should be level with the bottom of the filler hole.
  6.  
  7. If the fluid level is low, use Dexron® II automatic transmission fluid (or gear oil when applicable) to bring the fluid up to the proper level. Most parts stores will carry a small, hand operated pump which will greatly ease the task of adding fluid to the transfer case.
  8.  
  9. On all except the Bravada and the Typhoon, install the filler plug and torque it to 30-40 ft. lbs. (41-54 Nm). On the Bravada and the Typhoon, apply Loctite® to the filler plug and torque it to 80 inch lbs. (9 Nm).
  10.  

DRAIN AND REFILL



See Figure 2

  1. Operate the vehicle in four wheel drive in order to warm the fluid to normal operating temperature.
  2.  
  3. If necessary for access to the drain and filler plugs, raise and support the vehicle safely using jackstands. Support the truck so it is level; this is necessary to assure the proper fluid level is maintained when the case is refilled.
  4.  
  5. Position drain pan under transfer case.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Loosen and remove the lower plug (drain plug) in order to drain the fluid from the transfer case

  1. Remove drain and fill plugs, then drain the lubricant into the drain pan.
  2.  
  3. Install drain plug. Except for the Bravada and the Typhoon, torque the plug to 30-40 ft. lbs. (41-54 Nm). On the Bravada and the Typhoon, apply Loctite® to the drain plug and torque it to 80 inch lbs. (9 Nm).
  4.  
  5. Remove the drain pan and dump the fluid into a used transmission fluid storage tank, for recycling purposes.
  6.  
  7. Fill the transfer case to the edge of the fill plug opening.
  8.  
  9. Except for the Bravada and the Typhoon, install filler plug and torque it to 30-40 ft. lbs. (41-54 Nm). On the Bravada and the Typhoon, apply Loctite® to the filler plug and torque it to 80 inch lbs. (9 Nm).
  10.  
  11. Remove the jackstands and carefully lower the vehicle, then check for proper operation of the transfer case.
  12.  

 
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