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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 830 (Transfer Case - BW 4481-Nr3) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

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  1. Install the transfer case onto a suitable transmission jack.

    Important:  When installing a new transfer case gasket, the gasket must be installed with the tab oriented up, and the yellow printing towards to front of the vehicle. Install the gasket without the use of any type of sealant or of lubricant.

  2. Install a NEW transfer case gasket.
  3. Rotate the 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 to the adapter.
  7. Install the fuel pipe bracket onto the studs.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

    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).

    Fig 1: Installing Transfer Case To Adapter
    G01456434Courtesy of GENERAL MOTORS CORP.
  9. Position the crossmember.
  10. Install the crossmember bolts.

    Tighten 

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

    Fig 2: Installing Crossmember
    G01456435Courtesy of GENERAL MOTORS CORP.
  11. Install the transmission mount nuts.

    Tighten 

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

  12. Remove the jack stand from the transmission.
    Fig 3: Installing Transmission Mount Nuts
    G01456436Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel pipe clip to the fuel pipe bracket.
  14. Install the clips (5, 6) to the fuel pipe bracket.
  15. Position the speed sensor wire.
  16. Install the clip (3) to the transfer case bracket.
  17. Connect the speed sensor electrical connector (4).
  18. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT -- FRONT in Propeller Shaft.
  19. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT -- REAR in Propeller Shaft.
  20. Fill the transfer case with fluid.
  21. Install the transfer case shield, if equipped. Refer to TRANSFER CASE SHIELD REPLACEMENT  .
  22. Lower the vehicle.
    Fig 4: Connecting Speed Sensor Electrical Connector
    G01456437Courtesy of GENERAL MOTORS CORP.
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