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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1435 (Transfer Case - NVG 226-NP8) >> Repair Instructions >> Transfer Case Assembly Replacement (TrailBlazer, Envoy) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Transfer Case Adapter
    GM879658Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the transfer case gasket is damaged, replace it. DO NOT use silicone sealant in place or with the transfer case gasket.
    IMPORTANT: While installing the transfer case the front propeller shaft must be connected to the transfercase. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  1. Install or replace the transfer case gasket (4).
  2. Install the transfer case (3) in the vehicle.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the transfer case adapter (2) to transfer case nuts (5). Ensure the fuel line retainer (1) is in place.

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

  4. Remove the transmission jack stand.
    5. Fig 2: View Of Transfer Case Front Speed Sensor Electrical Connector
    GM746670Courtesy of GENERAL MOTORS CORP.
  5. Connect the electrical connectors to the speed sensors (front speed sensor shown).
    6. Fig 3: Disconnecting/Connecting Vent Hose
    GM747097Courtesy of GENERAL MOTORS CORP.
  6. Connect the vent hose.
  7. Connect the motor/encoder electrical connector.
    8. Fig 4: Removing/Installing Transfer Case Wiring Harness
    GM747103Courtesy of GENERAL MOTORS CORP.
  8. Install the transfer case harness to the transfer case.
    9. Fig 5: Removing/Installing Electrical Harness From Retainer
    GM747096Courtesy of GENERAL MOTORS CORP.
  9. Install the transfer case wiring harness to the retainers (left side).
    10. Fig 6: Removing/Installing Electrical Harness From Retainer
    GM747099Courtesy of GENERAL MOTORS CORP.
  10. Install the transfer case wiring harness to the retainers (right side).
    11. Fig 7: Removing/Installing Fuel Lines From Retainer
    GM747098Courtesy of GENERAL MOTORS CORP.
  11. Install the fuel lines to the retainer.
  12. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft.
  13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (TrailBlazer, Envoy, Rainier, Bravada)  or Transfer Case Fluid Replacement (TrailBlazer EXT, Envoy XL, Envoy XUV)  .
  14. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (TrailBlazer, Envoy) or Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
  15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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