Installation Procedure

WARNING: This page is about a different variant/trim than selected.

Place the transfer case onto a suitable transmission jack.
IMPORTANT: When installing a new transfer case gasket, the gasket must be installed with the locating tab oriented up, and the yellow printing towards the front of the vehicle. Install the gasket without the use of any type of sealant or lubricant.

Fig 1: View Of Transfer Case & Transmission
Courtesy of GENERAL MOTORS CORP.
Install a NEW transfer case gasket.
Rotate that transfer case so that it is parallel to the torsion bar mounting bracket.
Raise the transfer case into position.
Rotate the transfer case so that it is aligned with the adapter.
Install the transfer case.
Install the fuel pipe bracket onto the studs.
NOTE: Refer to FASTENER NOTICE .

IMPORTANT: Ensure that the gasket is flush to the transmission prior to installing the nuts.

Install the transfer case adapter nuts.
Tighten: Tighten the nuts to 50 N.m (37 lb ft).
Position the crossmember.

Fig 2: Identifying Crossmember & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the crossmember bolts.
Tighten: Tighten the bolts to 95 N.m (70 lb ft).
Install the transmission mount.

Fig 3: View Of Transmission Mount
Courtesy of GENERAL MOTORS CORP.
Install the transmission mount bolts (1), to the transfer case.

Fig 4: Locating Transmission Mount Bolts
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the bolts to 47 N.m (35 lb ft).
Lower the transfer case.
Install the transmission mount nuts.

Fig 5: Identifying Transmission Mount Nuts
Courtesy of GENERAL MOTORS CORP.

Tighten: Tighten the nuts to 40 N.m (30 lb ft).
Remove the jack stand from the transmission.
Remove the transmission jack from the transfer case.
Install the fuel pipe clip to the fuel pipe bracket.

Fig 6: Identifying Transmission/Transfer Case Components
Courtesy of GENERAL MOTORS CORP.
Install the clips (5, 6) to the fuel pipe bracket.
Position the speed sensor wire.
Install the speed sensor wire clip (3) to the bracket.
Connect the speed sensor electrical connector (4).
Install the transmission selector cable to the bracket.
Install the transmission vent hose clip to the bracket.
Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece .
Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front .
Refill the transfer case with fluid.
Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .