S10 Pickup, Sonoma 2000-2004
Transfer Case Removal & Installation
Disconnect the negative battery cable.
Shift the transfer case into the
Drain the transfer case fluid.
Support the transfer case.
Remove or disconnect the following:
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
Remove all traces of old gasket material from the mating surfaces.
Fig. Typical transfer case-to-manual transmission mounting
Fig. Typical transfer case-to-automatic transmission mounting
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
Refill the transfer case.
Skid plate, if equipped
Negative battery cable