GM Full-Size Trucks 1988-1998 Repair Information

Transfer Case Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Transfer case-to-transmission adapters-NP205

  1. Raise and support the truck on jackstands.
  2.  
  3. Drain the transfer case.
  4.  
  5. Disconnect the speedometer cable.
  6.  
  7. On models equipped with the NP208 transfer case, place the case in the 4H position.
  8.  
  9. Remove the skid plate and if necessary, the crossmember support.
  10.  
  11. If necessary, on trucks with automatic transmission, disconnect the strut rod.
  12.  
  13. Tag and unplug all electrical connections and hoses from the transfer case.
  14.  
  15. On models equipped with the NP208 transfer case, remove the parking brake cable guide from the pivot on the right frame rail.
  16.  
  17. Matchmark the driveshafts, disconnect them, and remove them.
  18.  
  19. Disconnect the shift lever rod.
  20.  
  21. Support the transfer case and remove the bolts attaching the transfer case to transmission adapter.
  22.  
  23. Move the transfer case to the rear until the input shaft clears the adapter and lower the transfer case from the truck.
  24.  

To install:

Installation is the reverse of removal. Please note the following steps.

  1. On models equipped with the NP208 transfer case, when installing the transfer case, make sure its in the 4H position.
  2.  
  3. On models except those equipped with the NP208 transfer case and all 1996-98 models, tighten the transfer case-to-transmission adapter bolts to 24 ft. lbs. (32 Nm).
  4.  
  5. On models equipped with the NP208 transfer case, tighten the transfer case-to-transmission adapter bolts to 30 ft. lbs. (40 Nm).
  6.  
  7. On 1996-98 models, tighten the transfer case-to-transmission adapter bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. If necessary, tighten the transmission end bolts to 129 ft. lbs. (175 Nm); the transfer case end bolts to 35 ft. lbs. (47 Nm).
  10.  



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Fig. Fig. 2: Transfer case and related components-NP241



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Fig. Fig. 3: Transfer case and related components-BW 1370, BW4401 and BW4470

 
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