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Transfer Case: Installation

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2003 Pontiac Montana, 2003 Pontiac Aztek, 2003 Oldsmobile Silhouette, 2003 Chevrolet Venture, and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If you are replacing anything other than gaskets or seals, the transaxle-to-transfer case end play check must be performed. See TRANSAXLE-TO-TRANSFER CASE END PLAY  under ADJUSTMENTS.
  1. If you are replacing the transfer case, install the transfer case lower brace and lower brace bolts. DO NOT tighten the bolts. See Figure.
  2. Install a NEW transfer case seal. See Figure.
    NOTE: The oil dam must be installed with the notch aligned to the oil passage in the transaxle case. See Figure.
  3. Install the oil dam to the transaxle.
  4. Rotate the transaxle 90 degrees.
    WARNING: This component weighs approximately 60 pounds. Personal injury may result if you lift the component improperly.
  5. Install the transfer case to the transaxle. See Fig 1.
    Fig 1: Installing Transfer Case-To-Transaxle
    G00211869Courtesy of GENERAL MOTORS CORP.
  6. Install the transfer case bolts (1) and (2). See Figure. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Use the Torque Angle Meter Tool (J-36660-A) to rotate the bolts 160 degrees.
  7. Install the transfer case bolt (3). See Figure. Tighten the bolt to specification. See TORQUE SPECIFICATIONS . Use the torque angle meter tool to rotate the bolts 70 degrees.
  8. Install the transfer case bolts (4) and (5). See Figure. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  9. Install the transfer case side brace. See Figure.
  10. Install and tighten the transfer case side brace bolts in the order shown. See Figure. Tighten transfer case side brace bolts to specification. See TORQUE SPECIFICATIONS .
  11. Install the transfer case lower brace to transaxle bolt. See Figure. Tighten the bolt to specification. See TORQUE SPECIFICATIONS .
  12. Tighten the transfer case lower brace to transfer case bolts. See Fig 2. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
    Fig 2: Identifying Transfer Case Brace Bolts
    G00211870Courtesy of GENERAL MOTORS CORP.
  13. Install the output shaft to the transaxle.
  14. Install a new output shaft retaining ring. See Figure.
  15. Install the transaxle with the transfer case. Refer to appropriate REMOVAL & INSTALLATION article as follows:
  16. Install the vent hose (2) and the clamp (1) to the transfer case. See Figure.
  17. Install the vehicle speed sensor electrical connector. Tighten the engine brace mounting bolts to specification. See TORQUE SPECIFICATIONS .
  18. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  19. Install the transfer case drain plug and fill the transfer case with appropriate fluid to proper level. See appropriate SERVICING article.
  20. Install the transfer case lower brace. See REMOVAL & INSTALLATION in appropriate SERVICING article.
  21. Lower the vehicle.
  22. Inspect and adjust the transaxle fluid to appropriate level. See appropriate SERVICING article in AUTOMATIC TRANSMISSIONS.
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