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Home >> Chevrolet >> 2022 >> Tahoe PPV, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Transfer Case - Mp 3025 (NQH)) >> Repair Instructions - On Vehicle >> Transfer Case Assembly Replacement (L84, L87 without F47) >> Installation Procedure

Installation Procedure

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  1. GM5607494Courtesy of GENERAL MOTORS COMPANY

    Apply grease the length of the splines even with the top of the splines. Adhesives, Fluids, Lubricants, and Sealers 

  2. Transfer Case Adapter Gasket (3) - Install NEW
  3. Transfer Case (2) - Install
    4. CAUTION:

    Refer to Fastener Caution .

  4. Transfer Case Nut (1) - Install and tighten [3x] - Fastener Specifications 
  5. GM5607493Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Nut (1) - Install and tighten [3x] - Fastener Specifications 

  6. Transfer Case Vent Hose (2) - Connect
  7. Remove the transmission jack from the transfer case.
  8. GM5605434Courtesy of GENERAL MOTORS COMPANY

    Reposition the wiring harness and connect the wiring harness retainer (3) to the transfer case.

  9. Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
  10. Connect the transfer case two/four wheel drive actuator electrical connector (1).
  11. GM5590452Courtesy of GENERAL MOTORS COMPANY

    Transmission Mount (2) - Install

  12. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  13. Transmission Mount Bolt (1) - Install and tighten [2x] - Fastener Specifications
  14. GM4960510Courtesy of GENERAL MOTORS COMPANY

    Transmission Heat Shield (3) - Install

  15. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  16. Transmission Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
  17. Transmission Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
  18. GM5586237Courtesy of GENERAL MOTORS COMPANY

    Reposition the transmission wiring harness and connect the wiring harness retainer (1).

  19. GM5001113Courtesy of GENERAL MOTORS COMPANY

    Exhaust System Seal (1) - Right Side - Install NEW

  20. GM5001105Courtesy of GENERAL MOTORS COMPANY

    Exhaust System Seal (1) - Left Side - Install NEW

  21. GM5001076Courtesy of GENERAL MOTORS COMPANY

    Three-Way Catalytic Converter (1) - Install

  22. GM5587680Courtesy of GENERAL MOTORS COMPANY

    Transmission Support Crossmember (1) - Install

  23. GM5587684Courtesy of GENERAL MOTORS COMPANY

    Transmission Support Crossmember Bolt (3) - Install [4x]

  24. Transmission Support Crossmember Nut (2) - Install and tighten [4x] - Fastener Specifications
  25. Transmission Mount Nut (1) - Install and tighten [2x] - Fastener Specifications
  26. Remove the transmission jack.
  27. GM5590117Courtesy of GENERAL MOTORS COMPANY

    If equipped, position the wiring harness (2) as necessary then install the harness into the 3 wiring harness retainers (1).

  28. GM5584486Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Nut (1) - Right Side - Install and tighten [3x] - Fastener Specifications

  29. GM5584496Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Nut (1) - Left Side - Install and tighten [3x] - Fastener Specifications

  30. GM5001054Courtesy of GENERAL MOTORS COMPANY

    Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) - Connect

  31. Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
  32. GM5523023Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 2 - Connect

  33. GM5568855Courtesy of GENERAL MOTORS COMPANY

    Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 1 - Connect

  34. GM5525401Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

    Using a suitable tool, install and tighten the heated oxygen sensor bank 1 sensor 1 (1). Fastener Specifications

  35. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 1 - Connect
  36. GM5508826Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Heat Shield (2) - Install

  37. Exhaust Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
  38. GM5508824Courtesy of GENERAL MOTORS COMPANY

    Exhaust Front Pipe Heat Shield (2) - Install

  39. Exhaust Heat Shield Bolt (1) - Install and tighten - Fastener Specifications
  40. GM5591284Courtesy of GENERAL MOTORS COMPANY

    Propeller Shaft (1) - Install

  41. GM5591283Courtesy of GENERAL MOTORS COMPANY

    Align the propeller shaft using the previously created marks.

  42. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  43. Rear Propeller Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
  44. GM5620263Courtesy of GENERAL MOTORS COMPANY

    Transfer Case Front Output Shaft Boot (1) - Install

  45. Using the DT-35910  Drive Axle Seal Clamp Pliers (3), install and crimp the NEW transfer case front output shaft boot clamp (2) until the gap at the base of the ear (a) is 1.5 mm (0.059 in).
  46. GM5590596Courtesy of GENERAL MOTORS COMPANY

    Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers

  47. Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.
  48. Align the reference marks made between the transfer case front output shaft and the front axle propeller shaft.
  49. Front Axle Propeller Shaft (3) - Install
  50. GM5043426Courtesy of GENERAL MOTORS COMPANY

    If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:

    1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
    2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
    3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
    4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
  51. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
  52. Front Axle Propeller Shaft Washer (3) - Install [3x]
  53. Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
  54. GM5044025Courtesy of GENERAL MOTORS COMPANY

    Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.

  55. Using the DT-35910  Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
  56. GM5523087Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Refer to Component Fastener Tightening Caution .

    NOTE:

    A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

    Using a suitable tool, install and tighten the heated oxygen sensor bank 1 sensor 2 (1). Fastener Specifications

  57. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 2 - Connect
  58. Fill the transfer case to the appropriate level. Transfer Case Fluid Replacement 
  59. GM5536037Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister (1) - Install

  60. GM5579727Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Hose (2) - Connect [3x] - Plastic Collar Quick Connect Fitting Service

  61. Evaporative Emission Canister Bracket Bolt (1) - Install and tighten - Fastener Specifications
  62. GM5535961Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister Bracket Nut (1) - Tighten [2x] - Fastener Specifications

  63. Front Wheelhouse Liner - Left Side and Right Side - Install - Front Wheelhouse Liner Replacement
  64. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
  65. After replacing the transfer case, perform the transfer case range actuator learn. Transfer Case Range Actuator Learn 
  66. Inspect for Leaks
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