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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1767 (Transfer Case - NVG 900) >> Repair Instructions >> Transfer Case Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Installing PTU To Transmission
    GM928984Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the seal with transmission fluid prior to PTU installation.
  1. Inspect the transmission output shaft seal, replace if damaged.
  2. Install the PTU to transmission. Ensure the PTU is fully engaged. Hand start the PTU to transmission bolts. DO NOT tighten.
    3. Fig 2: View Of Transfer Case Mounting Bracket
    GM928962Courtesy of GENERAL MOTORS CORP.
  3. Install the PTU brace. Hand start all 6 bolts.
    4. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Tighten the PTU to transmission bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  5. Tighten the PTU brace bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    6. Fig 3: Rear Transmission Bracket, Power Takeoff & Bolts
    GM928677Courtesy of GENERAL MOTORS CORP.
  6. Hand start all the powertrain mount to PTU bolts and tighten.
    7. Fig 4: View Of Propeller Shaft
    GM928930Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use the index mark for reassembly.
  7. Hand start the propshaft center bearing bolts.
  8. Ensure all the PTU flange and propshaft coupling area is clean. Insert coupling into the PTU flange.
    9. IMPORTANT: Apply Permatex Threadlocker®-Blue to bolt threads.
  9. Hand start all propshaft coupling bolts and tighten.

    Tighten:  Tighten the bolts to 25 N.m (19 lb ft).

    10. Fig 5: View Of Propeller Shaft, Support Bearing & Bolts
    GM928924Courtesy of GENERAL MOTORS CORP.
  10. Install the center bearing bolts.

    Tighten:  Tighten the bolts to 25 N.m (19 lb ft).

  11. Install the intermediate drive shaft. Refer to Intermediate Shaft Replacement in Wheel Drive Shafts.
  12. Position the steering gear mounts to the cradle. Refer to Power Steering Gear Replacement .
  13. Install the PTU vent hose.
    14. Fig 6: Checking PTU Fluid Fill
    GM737270Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use sealant GM P/N 12345493 or equivalent on fill plug.
  14. Check the PTU fluid fill. Remove the fluid fill plug. Fill until fluid is just below the bottom of the fill hole.

    Specification:  Add 500 ml (17 oz) PTU fluid.

    Tighten:  Tighten the fill plug to 15 N.m (11 lb ft).

  15. Lower the vehicle.
  16. Start the engine and observe idle shape. Compare to pre-removal condition. If excessive, perform powertrain balance procedure-operation #1. Refer to Powertrain Balance procedure.
  17. Check the transmission oil level and fill as required. Refer to LUBRICATION .
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