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Transfer Case - Removal & Installation Chevrolet Chevy Express H2500

Transfer Case 3 illustrations ~410 words

APPLICATION

ApplicationTransfer Case Model (RPO Code)
Express & SavanaBW 4473 (NP3)

TRANSFER CASE APPLICATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
CAUTIONUse the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Scheme 19

Scheme 19: Removal
Scheme 19: Removal

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Raise the vehicle.
  2. Remove the transmission support member. See «REMOVAL & INSTALLATION - "G" SERIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation) article in AUTOMATIC TRANSMISSIONS.
  3. Drain the transfer case. See «LUBRICATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/transfer-case/#transfer-case-servicing) in SERVICING - EXPRESS & SAVANA article.
  4. Remove the rear and front drive shafts from the transfer case. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Remove the vent hose from the transfer case. (Scheme 19)
  6. Disconnect the electrical connector from the speed sensor. (Scheme 20)
  7. Unclip the fuel lines from the fuel line bracket.
  8. Install a suitable transmission jack to the transfer case.
  9. Remove the nuts from the transfer case to the adapter. NOTE: Pull straight back on the transfer case in order to position the transfer case so that the transfer case can be turned parallel to the transmission.
  10. Remove the transfer case from the transfer case adapter. (Scheme 21)
  11. Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
  12. Lower the transfer case.
  13. Remove the gasket from the transfer case.
  14. Remove the transfer case from the transmission jack.

Note. When installing a new transfer case gasket, ensure that the locator tab is facing up for proper installation. Install the gasket without the use of any type of sealant or of lubricant.

  1. Install the transfer case on a suitable transmission jack.
  2. Install a new transfer case adapter gasket. (Scheme 21)
  3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
  4. Raise the transfer case into position.
  5. Rotate the transfer case so that the transfer case is aligned with the adapter.
  6. Install the transfer case on the adapter.
  7. Install the mounting nuts for the transfer case. Tighten the mounting nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/transfer-case/#transfer-case-removal-installation__torque-specifications).
  8. Install the transmission support member. See «REMOVAL & INSTALLATION - "G" SERIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation) article in AUTOMATIC TRANSMISSIONS.
  9. Remove the transmission jack.
  10. Install the electrical connector to the speed sensor. (Scheme 20)
  11. Install the vent hose to the vent tube. (Scheme 19)
  12. Install the fuel lines to the fuel line bracket.
  13. Install the front and rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  14. Fill the transfer case with the appropriate fluid to proper level. See «LUBRICATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/transfer-case/#transfer-case-servicing) in SERVICING - EXPRESS & SAVANA article.
  15. Lower the vehicle.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Transfer Case Mounting Nuts37 (50)

TORQUE SPECIFICATIONS

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