Installation Procedure

WARNING: This page is about a different car, the 2023 GMC Sierra 3500 HD and 2023 GMC Sierra 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

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Transfer Case Adapter Gasket (3) - Install NEW
Transfer Case (2) - Install

CAUTION:

Refer to Fastener Caution .

Transfer Case Nut (1) - Install and tighten [8x] - Fastener Specifications
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CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Transmission Mount (3) - Install NEW
Transmission Mount Heat Shield (1) - Install
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
Transmission Mount Bolt (2) - Install NEW and tighten [2X] - Fastener Specifications
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Transmission Support Crossmember (1) - Install
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Transmission Support Crossmember Bolt (1) - Install [4x]
Transmission Support Crossmember Nut (2) - Install and tighten [4x] - Fastener Specifications
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Transmission Mount Nut (1) - Install and tighten [2x] - Fastener Specifications
Remove the transmission jack.
Remove the transmission jack from the transfer case.
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Propeller Shaft (1) - Install
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Align the reference marks made between the rear wheel drive shaft flange and the propeller shaft (2).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications
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Connect the vent hose (1) to the transfer case.
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Loosely install a NEW front axle propeller shaft slip yoke boot clamp (2) to the front axle propeller shaft slip yoke boot (1) groove.
Front Axle Propeller Shaft Slip Yoke Boot (1) - Install
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Ensure the front axle propeller shaft slip yoke boot (1) is fully engaged into the groove of the transfer case output shaft.
Using the DT-35910 Drive Axle Seal Clamp Pliers (2), crimp the front axle propeller shaft slip yoke boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
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Apply a thin layer of grease to the front axle propeller shaft (3) splines. Adhesives, Fluids, Lubricants, and Sealers
Loosely install a NEW front axle propeller shaft slip yoke boot clamp (1) to the front axle propeller shaft slip yoke boot (2) groove.
Front Axle Propeller Shaft (3) - Install
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Align the reference marks made between the front axle propeller shaft and the front axle drive pinion flange.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
Front Axle Propeller Shaft Retainer (1) - Install [2x]
Front Axle Propeller Shaft Bolt (2) - Install and tighten [4x] - Fastener Specifications
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Ensure the front axle propeller shaft slip yoke boot (2) is fully engaged into the groove of the front axle propeller shaft.
Using the DT-35910 Drive Axle Seal Clamp Pliers (1), crimp the front axle propeller shaft slip yoke boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
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Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
Connect the transfer case two/four wheel drive actuator electrical connector (1).
Connect any wiring harness retainers to the transfer case.
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Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. Transfer Case Fluid Replacement
Install the negative battery cable to the battery. Battery Negative Cable Disconnection and Connection (without K4B)Battery Negative Cable Disconnection and Connection (with K4B)
After replacing the transfer case, perform the transfer case control module programming and setup. K69 Transfer Case Control Module: Programming and Setup (NQF)K69 Transfer Case Control Module: Programming and Setup (NQH)
Start the vehicle and shift the transfer case through all modes and ranges to verify correct operation.