Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Important: If you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed.

If you are replacing the transfer case, install the transfer case lower brace (906) and the lower brace bolts (903). Do not tighten the bolts.

Fig 1: Installing Transfer Case Lower Brace Bolts
Courtesy of GENERAL MOTORS CORP.
Install a new seal transfer case seal (1).

Fig 2: Installing Transfer Case Seal
Courtesy of GENERAL MOTORS CORP.
Rotate the transaxle 90 degrees.
CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component Improperly.
Install the transfer case to the transaxle.

Fig 3: Installing Transfer Case To Transaxle
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the transfer case bolts (1) and (2).
Tighten

Tighten the bolts to 35 N.m (26 lb ft).
Use the J 36660-A to rotate the bolts 160 degrees.
Install the transfer case bolt (3).
Tighten

Tighten the bolt to 35 N.m (26 lb ft).
Use the J 36660-A to rotate the bolts 70 degrees.
Install the transfer case bolts (4) and (5).
Tighten

Tighten the bolts to 40 N.m (30 lb ft).

Fig 4: Installing Transfer Case Bolts
Courtesy of GENERAL MOTORS CORP.
Install the transfer case side brace (905).
Install the tighten the transfer case side brace bolts in the order shown.
Tighten

Tighten transfer case side brace bolts to 32N.m (24 lb ft).

Fig 5: Installing Transfer Case Side Brace And Tightening Bolts
Courtesy of GENERAL MOTORS CORP.
Install the transfer case lower brace to transaxle bolt (1).
Tighten

Tighten the bolt to 56N.m (42 lb ft).

Fig 6: Installing Transfer Case Lower Brace Bolt
Courtesy of GENERAL MOTORS CORP.
Tighten the transfer case lower brace to transfer case bolts (903).
Tighten

Tighten the bolts to 32N.m (24 lb ft).

Fig 7: Tightening Transfer Case Lower Brace Bolt
Courtesy of GENERAL MOTORS CORP.
Install the output shaft to the transmission. Refer to Automatic Transaxle - 4T65-E Unit Repair.
Install a new output shaft retaining ring (1).
Install the transaxle with the transfer case. Refer to TRANSMISSION REPLACEMENT (M15) or TRANSMISSION REPLACEMENT (M76) in Automatic Transaxle - 4T65-E.

Fig 8: Installing Output Shaft Retaining Ring
Courtesy of GENERAL MOTORS CORP.
Install the vent hose (2) and the clamp (1) to the transfer case.
Install the vehicle speed sensor electrical connector.
Install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT in Propeller Shaft.
Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to TRANSFER CASE FLUID REPLACEMENT .

Fig 9: Installing Vent Hose To Transfer Case
Courtesy of GENERAL MOTORS CORP.
Install the drain plug (1) and gasket to the case.
Tighten

Tighten the drain plug to 32 N.m (24 lb ft).
Install the transfer case lower brace. Refer to SUPPORT BRACE REPLACEMENT .
Lower the vehicle.
Inspect and adjust the transmission fluid level. Refer to CHECKING FLUID LEVEL & CONDITION in Automatic Transaxle - 4T65-E.

Fig 10: Installing Drain Plug And Gasket To Transfer Case
Courtesy of GENERAL MOTORS CORP.