Installation Procedure

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

Important: The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer (located behind the transmission sun gear). The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components (excluding gaskets and seals) are replaced.

Perform the transmission-to-transfer case end play check. Refer to TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK .
Install the O-ring (1) seal to the transfer case.

Fig 1: Installing Transfer Case O-Ring Seal
Courtesy of GENERAL MOTORS CORP.
Rotate the transaxle so that the bottom pan is facing the floor.
Install the transfer case assembly to the transaxle.

Fig 2: Installing Transfer Case Assembly To Transaxle
Courtesy of GENERAL MOTORS CORP.
Install the transfer case-to-transaxle bolts and tighten the bolts in the following sequence:
NOTE: Refer to FASTENER NOTICE .
Tighten the transfer case-to-transaxle bolts (1) and (2).
Tighten
- First pass 35 N.m (26 lb ft).
- Final pass an additional 160 degrees.
Tighten the transfer case-to-transaxle bolt (3).
Tighten
- First pass 35 N.m (26 lb ft).
- Final pass an additional 70 degrees.
Tighten the transfer case-to-transaxle bolts (4) and (5).
Tighten

Tighten the transfer case-to-transaxle bolts (4) and (5) to 40 N.m (30 lb ft).

Fig 3: Installing Transfer Case-To-Transaxle Bolts
Courtesy of GENERAL MOTORS CORP.
Install the transfer case side brace (6).
Install the transfer case side brace-to-transaxle bolts. Hand tighten bolts.
Tighten the bolts in the following sequence (1, 2, 3, 4, 5).
Tighten

Tighten transfer case side brace bolts to 47 N.m (35 lb ft).

Fig 4: Installing Transfer Case Lower Brace-To-Transaxle Bolt
Courtesy of GENERAL MOTORS CORP.
Rotate the transaxle 90 degrees.
Install the transfer case lower brace-to-transaxle bolt (1).
Tighten

Tighten transfer case lower brace bolt to 47 N.m (35 lb ft).

Fig 5: Installing Transfer Case Lower Brace Bolt
Courtesy of GENERAL MOTORS CORP.
Install the output shaft to the transmission. Refer to OUTPUT SHAFT .
Install a new output shaft retaining ring (1),
Install the transaxle. Refer to TRANSMISSION REPLACEMENT (M15) or TRANSMISSION REPLACEMENT (M76) .

Fig 6: Installing Output Shaft Retaining Ring
Courtesy of GENERAL MOTORS CORP.
Install the vent hose (2) and coupling (1) to the extension housing.
Connect the clamp to the vent hose coupling.
Install the vent hose bracket and bolt/stud (3) to the transfer case.
Tighten

Tighten the bolt/stud to 10 N.m (106 lb in).
Connect the electrical connector to the speed sensor.
Install propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .

Fig 7: Installing Vent Hose, Coupling, Bolts & Extension Housing
Courtesy of GENERAL MOTORS CORP.
Install the transfer case lower brace.
Install the transfer case lower brace bolts.
Tighten

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

Fig 8: Installing Transfer Case Lower Brace & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the lubricant drain plug (1) and gasket to the case.
Tighten

Tighten the drain plug to 32 N.m (24 lb ft).
Inspect the transmission fluid level. Refer to CHECKING FLUID LEVEL & CONDITION .

Fig 9: Installing Lubricant Drain Plug
Courtesy of GENERAL MOTORS CORP.
Install the lubricant drain plug (1) and gasket to the extension housing.
Tighten

Tighten the drain plug to 32 N.m (24 lb ft).
Remove the extension housing fill plug (2) and gasket.
Fill the extension housing with synthetic gear oil GM P/N United
States 12378514 GM P/N Canada 88901045. Refer to Transfer Case Fluid Replacement .
Install the fill plug and gasket to the extension housing.
Tighten

Tighten the extension housing fill plug to 32 N.m (24 lb ft).
Lower the vehicle.

Fig 10: Installing Propeller Shaft & Bolts
Courtesy of GENERAL MOTORS CORP.