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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1028 (Transfer Case - NVG 261-NP2) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: The following installation procedure must be performed with the assistance of another technician.
  1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
  2. Rotate the transfer case so that it is in line with the adapter.
  3. Install the transfer case.
    4. Fig 1: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
  4. Install the shift control switch harness bracket.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the transfer case adapter nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

    6. Fig 2: Installing Transfer Case Adapter Nuts
    GM715663Courtesy of GENERAL MOTORS CORP.
  6. Install the transmission mount.
    7. Fig 3: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission mount bolts.

    Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

    8. Fig 4: Installing Transmission Mount Bolts
    GM715661Courtesy of GENERAL MOTORS CORP.
  8. Install the crossmember.
  9. Install the crossmember bolts.

    Tighten:  Tighten the bolts to 70 N.m (52 lb ft).

    10. Fig 5: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  10. Lower the transfer case and transmission onto the transmission support.
  11. Install the transmission mount nuts.

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

    12. Fig 6: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  12. Remove the support from the transfer case.
  13. Remove the transmission jack stand.
  14. Install the control rod. Refer to Transfer Case Control Rod Replacement .
  15. Install the vent hose.
    16. Fig 7: Installing Vent Hose
    GM715667Courtesy of GENERAL MOTORS CORP.
  16. Position the harness.
  17. Install the harness clips (3) to the transfer case.
  18. Connect the speed sensor electrical connector (4).
  19. Connect the gear indicator switch electrical connector (2).
  20. Install the in-line to engine harness electrical connector (1) to the bracket.
    21. Fig 8: Transfer Case Electrical Connectors & Harness Clips
    GM860643Courtesy of GENERAL MOTORS CORP.
  21. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece in Propeller Shaft.
  22. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  23. Check the fluid level. Add fluid if necessary.
  24. Install the transfer case shield, if equipped. Refer to Transfer Case Speed Sensor Replacement .
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