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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 861 (Transfer Case - STEYR) >> Repair Instructions >> Transfer Case And/Or Seal Replacement >> Tools Required

Tools Required

WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Important:  Transmission oil circulates between the transmission and the transfer case. In situations where transmission failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

  1. Raise and support the vehicle.
  2. Remove the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
  3. Remove the drain plug (1) drain the transfer case oil.
  4. Remove the drain plug (1) in order to drain the transmission fluid.
  5. Disconnect the vehicle speed sensor electrical connector.
  6. Remove the transfer case brace. Refer to SUPPORT BRACE REPLACEMENT  .
    Fig 1: Removing Drain Plug
    G01499978Courtesy of GENERAL MOTORS CORP.
  7. Remove the vent tube clamp (1).
  8. Separate the vent tube from the vent tube bracket.
  9. Remove the vent tube from the transfer case.
    NOTE: Removal and installation of the transfer case while the transmission is in vehicle may cause improper positioning of the park gear thrust bearing. If the transfer case fasteners are tightened while the park gear thrust bearing is out of position, the park gear thrust bearing, transmission, and/or the transfer case will be damaged.
  10. Remove the transfer case with the transaxle.

    Refer to TRANSAXLE .

  11. Install the transaxle to the transmission support fixture.
    Fig 2: Removing Vent Tube From Transfer Case
    G01499979Courtesy of GENERAL MOTORS CORP.
  12. Remove and discard the left output shaft retaining ring (1).
    Fig 3: Removing And Discard Left Output Shaft Retaining Ring
    G01499980Courtesy of GENERAL MOTORS CORP.
  13. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
    Fig 4: Rotating Transaxle 90 Degrees So That Transmission Side Cover Is Facing Down
    G01499981Courtesy of GENERAL MOTORS CORP.
  14. Rotate the transaxle 90 degrees.
  15. Remove the transfer case side brace bolts (1 through 5), and the transfer case side brace (6).
    Fig 5: Removing Transfer Case Side Brace Bolts And Transfer Case Side Brace
    G01499982Courtesy of GENERAL MOTORS CORP.
    Fig 6: Removing Transfer Case Bolts
    G01499983Courtesy of GENERAL MOTORS CORP.
  16. Remove the transfer case bolts (1 through 5).
    CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
    NOTE: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.
  17. Remove the transfer case (1) with the output shaft (2) from the transaxle (3).
    Fig 7: Removing Transfer Case With Output Shaft Transaxle
    G01499984Courtesy of GENERAL MOTORS CORP.
  18. Install the transfer case assembly to the J 44755. 
  19. Install the retaining bolts.

    Tighten 

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

    Fig 8: Installing Retaining Bolts
    G01499985Courtesy of GENERAL MOTORS CORP.
  20. Attach the J 6125-1B  to the J 44467. 
  21. Install the J 44467  into the snap ring groove on the output shaft (510) and tighten securely.
  22. Use the J6125-1Band  the J 44467  to remove the output shaft.
  23. Remove the output shaft from the transfer case.
    Fig 9: Installing J 44467 Into Snap Ring Groove On Output Shaft (510)
    G01499986Courtesy of GENERAL MOTORS CORP.

    Perform the following steps.

  24. Remove the transfer case seal (1) from the transfer case (2).
    Fig 10: Removing Transfer Case Seal
    G01499987Courtesy of GENERAL MOTORS CORP.
  25. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).
    Fig 11: Removing Transfer Case Lower Brace Bolts
    G01499988Courtesy of GENERAL MOTORS CORP.

    Installation Procedure 

    Important:  If you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed. Refer to Transmission to Transfer Case End Play Check (F4WD Only)  in appropriate Transmission article.

    1. If you are replacing the transfer case, install the transfer case lower brace (906) and the lower brace bolts (903). Do not tighten the bolts.
      Fig 12: Installing Transfer Case Lower Brace Bolts
      G01499989Courtesy of GENERAL MOTORS CORP.
    2. Install a new seal transfer case seal (1).
      Fig 13: Installing Seal Transfer Case Seal
      G01499990Courtesy of GENERAL MOTORS CORP.
    3. Rotate the transaxle 90 degrees.
      CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
    4. Install the transfer case to the transaxle.
      Fig 14: Installing Transfer Case To Transaxle
      G01499991Courtesy of GENERAL MOTORS CORP.
    5. Install the transfer case bolts (1) and (2).

      Tighten 

      1. 5.1. Tighten the bolts to 35 N.m (26 lb ft).
      2. 5.2. Use the J 36660-A  to rotate the bolts 160 degrees.
    6. Install the transfer case bolt (3).

      Tighten 

      1. 6.1. Tighten the bolt to 35 N.m (26 lb ft).
      2. 6.2. Use the J 36660-A  to rotate the bolts 70 degrees.
    7. Install the transfer case bolts (4) and (5).

      Tighten 

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

      Fig 15: Locating Transfer Case Installing Bolts
      G01499993Courtesy of GENERAL MOTORS CORP.
    8. Install the transfer case side brace (905).
    9. Install and tighten the transfer case side brace bolts in the order shown.

      Tighten 

      Tighten transfer case side brace bolts to 32N.m (24 lb ft).

      Fig 16: Locating Transfer Case Side Brace Bolts Installing Bolts
      G01499992Courtesy of GENERAL MOTORS CORP.
    10. Install the transfer case lower brace to transaxle bolt (1).

      Tighten 

      Tighten the bolt to 56N.m (42 lb ft).

    11. Tighten the transfer case lower brace to transfer case bolts (903).

      Tighten 

      Tighten the bolts to 32N.m (24 lb ft).

      Fig 17: Tightening Transfer Case Lower Brace To Transfer Case Bolts
      G01499994Courtesy of GENERAL MOTORS CORP.
    12. Install the output shaft to the transmission.
    13. Install a new output shaft retaining ring (1).
    14. Install the transaxle with the transfer case. Refer to TRANSAXLE .
      Fig 18: Installing Output Shaft Retaining Ring
      G01499995Courtesy of GENERAL MOTORS CORP.
    15. Install the vent hose (2) and the clamp (1) to the transfer case.
    16. Install the vehicle speed sensor electrical connector.
    17. Install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
    18. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to TRANSFER CASE FLUID REPLACEMENT  .
      Fig 19: Installing Vent Hose And Clamp To Transfer Case
      G01499996Courtesy of GENERAL MOTORS CORP.
    19. Install the drain plug (1) and gasket to the case.

      Tighten 

      Tighten the drain plug to 32 N.m (24 lb ft).

    20. Install the transfer case lower brace. Refer to SUPPORT BRACE REPLACEMENT  .
    21. Lower the vehicle.
    22. Inspect and adjust the transmission fluid level.
      Fig 20: Installing Drain Plug
      G01499997Courtesy of GENERAL MOTORS CORP.
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