GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Transfer Case

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REMOVAL & INSTALLATION



See Figures 1 through 7



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Fig. Fig. 1: If equipped, disconnect the shift cable linkage



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Fig. Fig. 2: Unplug the vacuum harness



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Fig. Fig. 3: With the transfer case supported, remove the transfer case retainer bolts



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Fig. Fig. 4: Carefully lower the transfer case from the vehicle on a transmission jack



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Fig. Fig. 5: Prior to installation, remove the old gasket from the mating surfaces



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Fig. Fig. 6: View of the transfer case shield

  1. Disconnect the negative battery cable.
  2.  
  3. Shift the transfer case into the 4WD High range.
  4.  
  5. Raise and support the vehicle safely using jackstands.
  6.  
  7. Remove the transfer case shield bolts, then remove the shield from under the transfer case assembly.
  8.  
  9. Remove the plug and drain the transfer case fluid.
  10.  
  11. Matchmark and remove the front and rear driveshafts from the transfer case.
  12.  
  13. Tag and disconnect the vacuum lines and/or the electrical connectors, as equipped.
  14.  
  15. Disconnect the transfer case shift rod or cable from the case, if applicable.
  16.  
  17. If applicable, remove the support brace-to-transfer case bolts.
  18.  
  19. Support the transfer case using a floor jack, then remove the transfer case-to-transmission retaining bolts
  20.  
  21. Slide the transfer case rearward and off the transmission output shaft, then careful lower it from the vehicle.
  22.  
  23. Remove all traces of old gasket material from the mating surfaces.
  24.  

To install:
  1. Installation is the reverse of removal, but please pay special attention to the following important steps.
  2.  
  3. Using the floor jack, carefully raise the transfer case into position behind the transmission. Position a new gasket, using sealer to hold it in position, then slide the transfer case onto the transmission output shaft.
  4.  
  5. Tighten the transfer case-to-transmission retaining bolts to 24 ft. lbs. (33 Nm) on 1994 vehicles, 41 ft. lbs. (55 Nm) on 1995-98 vehicles or 33-35 ft. lbs. (45-47 Nm) on 1999 models.
  6.  
  7. If equipped, tighten the support brace bolts to 35 ft. lbs. (47 Nm) on 1994-95 vehicles, or 35-37 ft. lbs. (47-50 Nm) on 1996-99 vehicles.
  8.  



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Fig. Fig. 7: Removing the left side support brace from the transmission/transfer case assembly-manual unit shown

 
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