Transfer Case and/or Seal Replacement
Transfer Case and/or Seal ReplacementRemoval Procedure
1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Remove propeller shaft.
3. Remove the drain plug (1) and gasket from the extension housing. Allow the gear oil to drain.
4. Remove the drain plug (1) and gasket from the case. Allow the transmission fluid to drain.
5. Disconnect the electrical connector from the speed sensor.
6. Remove the transfer case lower brace bolts.
7. Remove the transfer case lower brace.
8. Remove the clamp (1) and the bolt/stud (3) from the extension housing vent tube (2).
9. Remove the vent tube from the extension housing.
10. Remove the transaxle.
11. Remove and discard the output shaft;retaining ring (1).
12. Rotate the transaxle 90 degrees.
13. Remove the transfer case lower brace bolt (1).
14. Rotate the transaxle 90 degrees, to the installed position.
15. Remove the transfer case side brace bolts (1 through 5), and the side brace (6).
16. Remove the transfer case-to-transaxle bolts (1 through 5).
Caution: This component weighs approximately 60 lbs. Personal Injury may result If you lift the component improperly.
17. Remove the transfer case assembly (1) from the transaxle (3). Note that the transaxle output shaft (2) withdraws from the transaxle with the transfer case assembly.
18. Remove the output shaft (2).
19. Remove the transfer case O-ring seal (1) from the transfer case (2).
Installation Procedure
1. Install the O-ring seal (1) to the transfer case (2).
2. Rotate the transaxle 90 degrees to the installed position.
Caution: This component weighs approximately 60 lbs. Personal Injury may result If you lift the component improperly.
3. Install the transfer case assembly to the transaxle.
4. Install the transfer case-to-transaxle bolts and tighten the bolts in the following sequence:
Notice: Refer to Fastener Notice in Service Precautions.
5. Tighten the transfer case-to-transaxle bolts (1) and (2).
^ First pass 35 Nm (26 ft. lbs.).
^ Final pass an additional 160 degrees.
6. Tighten the transfer case-to-transaxle bolt (3).
^ First pass 35 Nm (26 ft. lbs.).
^ Final pass an additional 70 degrees.
7. Tighten the transfer case-to-transaxle bolts (4) and (5).
^ Tighten the transfer case-to-transaxle bolts (4) and (5) to 40 Nm (30 ft. lbs.).
8. Install the transfer case side brace (6).
9. Install the transfer case side brace-to-transaxle bolts. Hand tighten bolts.
10. Tighten the bolts in the following sequence (1, 2, 3, 4, 5).
^ Tighten transfer case side brace bolts to 47 Nm (35 ft. lbs.).
11. Rotate the transaxle 90 degrees.
12. Install the transfer case lower brace-to-transaxle bolt (1).
^ Tighten transfer case lower brace bolt to 47 Nm (35 ft. lbs.).
13. Install the output shaft to the transmission.
14. Install a new output shaft retaining ring (1).
15. Install the transaxle.
16. Install the vent hose (2) to the extension housing.
17. Install the clamp (1) and the bolt/stud (3) to the extension housing vent hose.
^ Tighten the bolt/stud to 10 Nm (106 inch lbs.).
18. Connect the electrical connector to the speed sensor.
19. Install propeller shaft.
20. Install the lubricant drain plug (1) and gasket to the extension housing.
^ Tighten the drain plug to 32 Nm (24 ft. lbs.).
21. Remove the extension housing fill plug (2) and gasket.
22. Fill the extension housing with synthetic gear oil GM P/N United States 12378514 GM P/N Canada 88901045.
23. Install the fill plug and gasket to the extension housing.
^ Tighten the extension housing fill plug to 32 Nm (24 ft. lbs.).
24. Install the drain plug (1) and gasket to the case.
^ Tighten the drain plug to 32 Nm (24 ft. lbs.).
25. Inspect the transmission fluid level.
26. Lower the vehicle.
27. Install the transfer case lower brace.
28. Install the transfer case lower brace bolts.
^ Tighten the brace bolts to 47 Nm (35 ft. lbs.).