S10 Pickup, Sonoma 2000-2004

Transfer Case Removal & Installation


  1. Disconnect the negative battery cable.
  3. Shift the transfer case into the 4HI range.
  5. Drain the transfer case fluid.
  7. Support the transfer case.
  9. Remove or disconnect the following:

    Skid plate
    Front and rear driveshafts from the transfer case. Matchmark the shafts prior to removal.
    Vacuum lines and/or the electrical connectors, as equipped
    Transfer case shift rod/cable from the case, if applicable
    Support brace-to-transfer case bolts, if applicable
    Transfer case

  11. Remove all traces of old gasket material from the mating surfaces.

    Click image to see an enlarged view

    Fig. Typical transfer case-to-manual transmission mounting

    Click image to see an enlarged view

    Fig. Typical transfer case-to-automatic transmission mounting


To install:

  1. Install or connect the following:

    New gasket using sealer to hold it in position
    Transfer case. Torque the bolts to 33-35 ft. lbs. (45-47 Nm).
    Support brace bolts. Torque the bolts to 35-37 ft. lbs. (47-50 Nm), if equipped.
    Shift rod to the case, if equipped
    Vacuum lines and/or electrical connections, as necessary
    Front and rear driveshafts by aligning the matchmarks

  3. Refill the transfer case.

    Skid plate, if equipped
    Negative battery cable