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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different car >> Section 411 (Transfer Case - BW 4482-Nr4) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Yukon XL and 2004 GMC Yukon. However, it is still accessible from the selected car via links, so may be relevant.
  1. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
  2. Raise the transfer case into position.
  3. Rotate the transfer case so that the transfer case aligns with the transfer case adapter.
  4. Install the transfer case.
  5. Install the fuel feed and return pipe bracket.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the transfer case adapter nuts.

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

    7. Fig 1: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission mount.
    8. Fig 2: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  8. Install the transmission mount bolts.

    Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

    9. Fig 3: Locating Transmission Mount
    GM715661Courtesy of GENERAL MOTORS CORP.
  9. Install the crossmember.
  10. Install the crossmember bolts.

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

    11. Fig 4: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  11. Install the transmission mount nuts.

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

    12. Fig 5: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  12. Remove the transmission jacks from the transmission and transfer case.
  13. Position the harness to the transfer case.
  14. Install the harness clips to the transfer case.
  15. Connect the speed sensor electrical connectors (1).
  16. Connect the encoder motor electrical connector (2).
  17. Install the harness inline to engine harness connector clip to the fuel feed and return pipe bracket.
    18. Fig 6: View Of Speed Sensor & Encoder Motor Electrical Connectors
    GM856630Courtesy of GENERAL MOTORS CORP.
  18. Position the vent hose to the transfer case.
  19. Install the vent hose (2) to the transfer case fitting (1).
    20. Fig 7: View Of Vent Hose To Transfer Case Fitting
    GM829842Courtesy of GENERAL MOTORS CORP.
  20. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft.
  21. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  22. Fill the transfer case with fluid.
  23. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
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