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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different car >> Section 413 (Transfer Case - BW 4481-Nr3) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Cadillac Escalade EXT, 2004 Cadillac Escalade ESV, and 2004 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the transfer case onto a suitable transmission jack.
    2. 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.
    8. 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).

    9. Fig 1: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
  9. Position the crossmember.
  10. Install the crossmember bolts.

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

    11. Fig 2: 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 3: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  12. Remove the jack stand from the transmission.
  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. Fig 4: View Of Speed Sensor Electrical Connectors & Bracket Clips
    GM826962Courtesy of GENERAL MOTORS CORP.
  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.
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