Transfer Case Assembly Replacement

WARNING: This page is about a different car, the 2009 GMC Yukon, 2009 Chevrolet Tahoe, 2009 Chevrolet Suburban, and 2009 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Transfer Case Assembly Replacement

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
Preliminary Procedures Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement . Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement . Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement . Drain the fluid from the transfer case. Refer to Transfer Case Fluid Replacement . Disconnect the electrical connectors and remove the electrical harness from the transfer case. Remove the crossmember. Refer to Transmission Support Crossmember Replacement (4WD 2500 Series) or Transmission Support Crossmember Replacement (4WD 1500 Series) or Transmission Support Crossmember Replacement (2WD 2500 Series) or Transmission Support Crossmember Replacement (2WD 1500 Series) . Remove the transmission mount. Refer to Transmission Mount Replacement (4WD) for the 4L60-E/4L65-E/4L70-E transmission, or Transmission Mount Replacement (4WD) for the 6L50/6L80/6L90 transmission.
1	Transfer Case Nut CAUTION: Refer to Fastener Caution . Tighten: 50 N.m (37 lb ft)
2	Transfer Case Procedure: If installing a new or repaired transfer case, preform the Transfer Case High/Low Clutch reset. Refer to Transfer Case High/Low Clutch Reset .
3	Transfer Case Gasket Procedure Install a NEW gasket without the use of any type of sealant or lubricant. Apply GM /P/N 12345879 (Canadian P/N 10953511) or equivalent lubricant meeting GM Specification 9985830 to the input shaft splines.