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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 831 (Transfer Case - BW 4482-Nr4) >> Repair Instructions >> Transfer Case Assembly Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Yukon XL, 2003 GMC Yukon, 2003 Chevrolet Tahoe, 2003 Chevrolet Suburban, and 2003 Cadillac Escalade ESV. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the transfer case shield, if equipped. Refer to TRANSFER CASE SHIELD REPLACEMENT .
  2. Drain the transfer case fluid.
  3. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
  4. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
  5. Remove the vent hose (2) from the transfer case fitting (1).
  6. Reposition the vent hose out of the way.
    Fig 1: Removing Vent Hose From Transfer Case Fitting
    G01456516Courtesy of GENERAL MOTORS CORP.
  7. Remove the harness in-line to engine harness connector clip from the fuel feed and return pipe bracket.
  8. Disconnect the encoder motor electrical connector (2).
  9. Disconnect the speed sensor electrical connectors (1).
  10. Remove the harness clips from the transfer case.
  11. Reposition the harness out of the way.

    Important:  Ensure that the transfer case is correctly secured to the transmission jack.

  12. Support the transmission and transfer case with suitable transmission jacks.
    Fig 2: Disconnect Encoder Motor And Speed Sensor Electrical Connector
    G01456517Courtesy of GENERAL MOTORS CORP.
  13. Remove the transmission mount nuts.
    Fig 3: Removing Transmission Mount Nuts
    G01456518Courtesy of GENERAL MOTORS CORP.
  14. Remove the crossmember bolts.
  15. Remove the crossmember.
    Fig 4: Removing Crossmember
    G01456519Courtesy of GENERAL MOTORS CORP.
  16. Remove the transmission mount bolts.
    Fig 5: Removing Transmission Mount Bolts
    G01456520Courtesy of GENERAL MOTORS CORP.
  17. Remove the transmission mount.
    Fig 6: Removing Transmission Mount
    G01456521Courtesy of GENERAL MOTORS CORP.
  18. Remove the transfer case adapter nuts.
  19. Remove the fuel feed and return pipe bracket.
  20. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle.
  21. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
  22. Lower the transfer case.
    Fig 7: Removing Transfer Case Adapter
    G01456522Courtesy of GENERAL MOTORS CORP.
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