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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1033 (Transfer Case - NVG 149-NP3) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When installing a new transfer case gasket, the gasket must be installed with the locating tab oriented up, and the yellow printing towards the front of the vehicle. Install the gasket without the use of any type of sealant or lubricant.
  1. Place the transfer case onto a suitable transmission jack.
  2. Install a NEW transfer case gasket.
  3. Rotate that transfer case so that it is parallel to the torsion bar mounting bracket.
  4. Raise the transfer case into position.
  5. Rotate the transfer case so that it is aligned with the adapter.
  6. Install the transfer case.
  7. Install the fuel pipe bracket onto the studs.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    8. IMPORTANT: Ensure that the gasket is flush to the transmission prior to installing the nuts.
  8. Install the transfer case adapter nuts.

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

  9. Position the crossmember.
  10. Install the crossmember bolts.

    Tighten:  Tighten the bolts to 95 N.m (70 lb ft).

    11. Fig 2: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  11. Install the transmission mount.
    12. Fig 3: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  12. Install the transmission mount bolts (1), to the transfer case.

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

    13. Fig 4: Locating Transmission Mount Bolts
    GM702771Courtesy of GENERAL MOTORS CORP.
  13. Lower the transfer case.
  14. Install the transmission mount nuts.

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

    15. Fig 5: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  15. Remove the jack stand from the transmission.
  16. Remove the transmission jack from the transfer case.
  17. Install the fuel pipe clip to the fuel pipe bracket.
  18. Install the clips (5, 6) to the fuel pipe bracket.
    19. Fig 6: Transfer Case Components
    GM826962Courtesy of GENERAL MOTORS CORP.
  19. Position the speed sensor wire.
  20. Install the speed sensor wire clip (3) to the bracket.
  21. Connect the speed sensor electrical connector (4).
  22. Install the transmission selector cable to the bracket.
  23. Install the transmission vent hose clip to the bracket.
  24. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece in Propeller Shaft.
  25. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  26. Refill the transfer case with fluid.
  27. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
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