GM Full-Size Trucks 1980-1987 Repair Guide

Transfer Case

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REMOVAL & INSTALLATION



See illustrations of 205 and 208 series transfer cases under Transmission Removal in this Section.

  1. Raise and support the truck.
  2.  
  3. Drain the transfer case.
  4.  
  5. Disconnect the speedometer cable, back-up light switch, and the TCS switch.
  6.  
  7. If necessary, remove the skid plate and crossmember support.
  8.  
  9. Disconnect the front and rear driveshafts and support them out of the way.
  10.  
  11. On New Process 205 models, disconnect the shift lever rod from the shift rail link.
  12.  
  13. Remove the transfer case-to-frame mounting bolts.
  14.  
  15. Support the transfer case and remove the bolts attaching the transfer case to transmission adapter.
  16.  
  17. Move the transfer case to the rear until the input shaft clears the adapter and lower the transfer case from the truck.
  18.  
  19. Installation is the reverse of removal.
  20.  

 
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