Drivetrain - Transfer Case Fluid Drain/Refill Procedure

INFORMATION

Bulletin No.: 08-04-21-004

Date: April 16, 2008

Subject:
Transfer Case Fluid Drain and Refill (All Wheel Drive (AWD))

Models:
2003-2009 Chevrolet Express AWD
2003-2009 GMC Savana AWD

This bulletin is being released to inform technicians of the need to add additional transfer case fluid through the threaded speed sensor opening.

Important:
When performing the following service procedure, use only hand tools to remove and install the fill or drain plugs.





1. Remove the transfer case drain plug and fill plug.

2. Apply pipe sealant, P/N 12346004 (in Canada ,P/N 10953480) to the threads of the transfer case drain plug and reinstall the drain plug.

Tighten

Tighten the transfer case drain plug to 25 N.m (18 lb ft).

3. Fill the transfer case to the bottom of the fill hole with DEXRON(R)VI fluid, P/N 88861003 (in Canada, P/N 88861004).

4. Apply pipe sealant, P/N 12346004 (in Canada, P/N 10953480) to the threads of the transfer case fill plug.

5. Install the transfer case fill plug.

Tighten:

Tighten the transfer case fill plug to 25 N.m (18 lb ft).





6. Disconnect the electrical connector from the speed sensor.





7. Remove the speed sensor and the 0-ring from the transfer case.

8. Add 1.0 Liter (1.06 quarts) of DEXRON(R)VI fluid, P/N 88861003 (in Canada, P/N 88861004) through the threaded speed sensor opening.

9. Install the speed sensor into the transfer case with the new 0-ring seal.

Tighten:

Tighten the speed sensor to 17 N.m (16 lb ft).

10. Connect the electrical connector to the speed sensor.

11. Lower the vehicle.





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