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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Transfer Case - NVG 263-NP1 - Service & Diagnosis) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
IMPORTANT: The following installation procedure must be performed with the assistance of another technician.
  1. Install the transfer case, perform the following:
    Fig 1: Installing Transfer Case Adapter Nuts
    GM715663Courtesy of GENERAL MOTORS CORP.
    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. Install the transmission mount.
  4. Install the transmission mount bolts.
    Fig 2: Installing Transmission Mount Bolts
    GM715661Courtesy of GENERAL MOTORS CORP.

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

  5. Install the crossmember.
    Fig 3: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  6. Install the crossmember bolts.

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

  7. Lower the transmission/transfer case.
  8. Install the transmission mount nuts.
    Fig 4: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.

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

  9. Remove the transmission jack stand.
  10. Connect the transfer case vent hose.
    Fig 5: Connecting Vent Hose
    GM715667Courtesy of GENERAL MOTORS CORP.
  11. Install the clips to the transfer case brackets.
  12. Connect the encoder motor electrical connector.
  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.
    Fig 6: Connecting Transfer Case Speed Sensor Electrical Connector
    GM662044Courtesy of GENERAL MOTORS CORP.
  16. Install the transmission vent hose clip to the bracket, if equipped.
    Fig 7: Installing Transmission Vent Hose Clip
    GM102222Courtesy of GENERAL MOTORS CORP.
  17. Install the transmission shift control cable clip to the transfer case.
  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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