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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1616 (Transfer Case - NVG 263-NP1 (SELECTABLE)) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 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. Install the transfer case, perform the following:
    1. 1.1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
    2. 1.2. Rotate the transfer case so that it is in line with the adapter.
    3. 1.3. Install the transfer case to the adapter.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the transfer case adapter nuts.

    Tighten 

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

    Fig 1: Transfer Case Adapter Nuts
    G01481375Courtesy of GENERAL MOTORS CORP.
  3. Install the transmission mount.
  4. Install the transmission mount bolts.

    Tighten 

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

    Fig 2: Transmission Mount Bolts
    G01481376Courtesy of GENERAL MOTORS CORP.
  5. Install the crossmember.
  6. Install the crossmember bolts.

    Tighten 

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

    Fig 3: Crossmember & Bolts
    G01481377Courtesy of GENERAL MOTORS CORP.
  7. Lower the transmission/transfer case.
  8. Install the transmission mount nuts.

    Tighten 

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

  9. Remove the transmission jack stand.
    Fig 4: Transmission Mount Nuts
    G01481378Courtesy of GENERAL MOTORS CORP.
  10. Connect the transfer case vent hose.
    Fig 5: Transfer Case Vent Hose
    G01481379Courtesy of GENERAL MOTORS CORP.
  11. Install the clips to the transfer case brackets.
  12. Connect the encoder motor electrical connector.
  13. Install the inline connector to the harness bracket.
  14. Connect the inline to engine harness electrical connector.
  15. Connect the speed sensor electrical connector.
    Fig 6: Speed Sensor Electrical Connector
    G01481380Courtesy of GENERAL MOTORS CORP.
  16. Install the transmission vent hose clip to the bracket, if equipped.
  17. Install the transmission shift control cable clip to the transfer case.
  18. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT-ONE PIECE  or  PROPELLER SHAFT REPLACEMENT-TWO PIECE  .
  19. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT-FRONT  .
  20. Fill the transfer case with fluid.
  21. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
    Fig 7: Transmission Shift Control Cable Clip
    G01481381Courtesy of GENERAL MOTORS CORP.
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