Transfer Case Assembly Replacement

Preliminary Procedures

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
3. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (1500)Rear Propeller Shaft Replacement (Heavy Duty)Rear Propeller Shaft Replacement (M5U, 2WD) .
4. Remove the front propeller shaft. Refer to Front Axle Propeller Shaft Replacement (NQH)Front Axle Propeller Shaft Replacement (Heavy Duty) .
5. Drain the fluid from the transfer case. Refer to Transfer Case Fluid Replacement .
6. Disconnect the electrical connectors and remove the electrical harness from the transfer case.
7. Remove the crossmember. Refer to Transmission Support Crossmember Replacement (2WD)Transmission Support Crossmember Replacement (4WD) .
8. Remove the transmission mount. Refer to Transmission Mount Replacement (Two Wheel Drive)Transmission Mount Replacement (Four Wheel Drive) .

Procedure

1. Install a NEW gasket without the use of any type of sealant or lubricant.
   NOTE: If installing a new or repaired transfer case, perform the Transfer Case High/Low Clutch reset. Refer to Transfer Case High/Low Clutch Reset .
2. For (dry cavity) applications only, apply lubricant meeting GM Specification 9985830 to the input shaft splines. Refer to Adhesives, Fluids, Lubricants and Sealers .
3. Disconnect the vent hose and position it aside.
4. Using a suitable jack, support the transfer case.