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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 998 (Transfer Case - NVG 263-NP1) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 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. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
    2. Rotate the transfer case so that it is in line with the adapter.
    3. Install the transfer case to the adapter.
      NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the transfer case adapter nuts.

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

    3. Fig 1: Installing Transfer Case Adapter Nuts
    GM715663Courtesy 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).

    5. Fig 2: Installing Transmission Mount Bolts
    GM715661Courtesy of GENERAL MOTORS CORP.
  5. Install the crossmember.
  6. Install the crossmember bolts.

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

    7. Fig 3: Identifying Crossmember & Bolts
    GM652595Courtesy 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. Fig 4: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  9. Remove the transmission jack stand.
  10. Connect the transfer case vent hose.
    11. Fig 5: Connecting Transfer Case Vent Hose
    GM715667Courtesy of GENERAL MOTORS CORP.
  11. Install the clips to the transfer case brackets.
  12. Connect the encoder motor electrical connector.
    13. Fig 6: Connecting Encoder Motor Electrical Connector
    GM662044Courtesy of GENERAL MOTORS CORP.
  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.
  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. Fig 7: Installing Transmission Shift Control Cable Clip
    GM102222Courtesy of GENERAL MOTORS CORP.
  18. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece in Propeller Shaft.
  19. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  20. Fill the transfer case with fluid.
  21. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
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