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Transfer Case - Removal & Installation: Removal & Installation Chevrolet Silverado 2500

Transfer Case 18 illustrations ~2197 words

Removal (NVG 149)

  1. Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).
  2. Remove the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Drain the transfer case fluid. See LUBRICATION in appropriate SERVICING article.
  4. Remove the transmission vent hose clip from the bracket.
  5. Remove the transmission selector cable from the bracket.
  6. Disconnect the speed sensor electrical connector (4). (Scheme 1)
  7. Remove the speed sensor wire clip (3) from the bracket. (Scheme 1)
  8. Reposition the speed sensor wire.
  9. Remove the engine harness clips (5 and 6) from the bracket. (Scheme 1)
  10. Remove the fuel pipe clip from the bracket.
  11. Support the transmission with a suitable jack stand.
  12. Install a suitable transmission jack under the transfer case.
  13. Remove the transmission mount nuts. (Scheme 2)
  14. Raise the transfer case slightly.
  15. Remove the transmission mount bolts at the transfer case.
  16. Remove the transmission mount.
  17. Remove the crossmember bolts. (Scheme 3)
  18. Remove the crossmember.
  19. Remove the transfer case adapter nuts.
  20. Remove the fuel pipe bracket from the studs. NOTE: Pull straight back on the transfer case in order to position the transfer case so that it can be rotated parallel to the transmission.
  21. Remove the transfer case. (Scheme 4)
  22. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
  23. Lower the transmission jack.
  24. Remove the gasket from the transfer case.
  25. Remove the transfer case from the transmission jack.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Installation (NVG 149)

  1. Place the transfer case onto a suitable transmission jack. NOTE: 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.
  2. Install a NEW transfer case gasket.
  3. Rotate that transfer case so that it is parallel to the torsion bar mounting bracket.
  4. Raise the transfer case into position.
  5. Rotate the transfer case so that it is aligned with the adapter.
  6. Install the transfer case. (Scheme 4)
  7. Install the fuel pipe bracket onto the studs. NOTE: Ensure that the gasket is flush to the transmission prior to installing the nuts.
  8. Install the transfer case adapter nuts. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  9. Position the crossmember.
  10. Install the crossmember bolts. (Scheme 3) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  11. Install the transmission mount.
  12. Install the transmission mount bolts to the transfer case. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  13. Lower the transfer case.
  14. Install the transmission mount nuts. (Scheme 2) Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  15. Remove the jack stand from the transmission.
  16. Remove the transmission jack from the transfer case.
  17. Install the fuel pipe clip to the fuel pipe bracket.
  18. Install the clips (5 and 6) to the fuel pipe bracket. (Scheme 1)
  19. Position the speed sensor wire.
  20. Install the speed sensor wire clip (3) to the bracket. (Scheme 1)
  21. Connect the speed sensor electrical connector (4). (Scheme 1)
  22. Install the transmission selector cable to the bracket.
  23. Install the transmission vent hose clip to the bracket.
  24. Install the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  25. Refill the transfer case with appropriate fluid to proper level. See appropriate SERVICING article.
  26. Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).

Removal (NVG 246)

  1. Remove transfer case shield. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).
  2. Remove the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Remove the vent hose (2) from the transfer case fitting (1). (Scheme 5)
  4. Reposition the vent hose out of the way.
  5. Remove the in-line harness-to-engine harness connector (1) clip from the fuel feed and return pipe bracket. (Scheme 6)
  6. Disconnect the encoder motor electrical connector (7). (Scheme 6)
  7. Disconnect the speed sensor electrical connectors (3, 4 and 5). (Scheme 6)
  8. Remove the harness clips (6 and 8) from the transfer case. (Scheme 6)
  9. Reposition the harness out of the way.
  10. Support the transfer case with a suitable transmission jack. CAUTION: Ensure the transfer case is correctly secured to the transmission jack.
  11. Remove the transfer case adapter nuts. CAUTION: When removing the transfer case from the transmission, do not remove the transmission mount or the transfer case adapter.
  12. Remove the fuel feed and return pipe bracket.
  13. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle. (Scheme 4)
  14. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
  15. Lower the transfer case.

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Installation (NVG 246)

  1. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
  2. Raise the transfer case into position.
  3. Rotate the transfer case so that the transfer case aligns with the transfer case adapter.
  4. Install the transfer case. (Scheme 4)
  5. Install the fuel feed and return pipe bracket.
  6. Install the transfer case adapter nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  7. Remove the transmission jack from the transfer case.
  8. Position the harness to the transfer case.
  9. Install the harness clips (6 and 8) to the transfer case. (Scheme 6)
  10. Connect the speed sensor electrical connectors (3, 4 and 5). (Scheme 6)
  11. Connect the encoder motor electrical connector (7). (Scheme 6)
  12. Install the in-line harness-to-engine harness connector (1) clip to the fuel feed and return pipe bracket. (Scheme 6)
  13. Position the vent hose to the transfer case.
  14. Install the vent hose (2) to the transfer case fitting (1). (Scheme 5)
  15. Install the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  16. Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).

Removal (NVG 261)

  1. Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).
  2. Remove the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Remove the in-line to engine harness electrical connector (1) from the bracket. (Scheme 7)
  4. Disconnect the gear indicator switch electrical connector (2). (Scheme 7)
  5. Disconnect the speed sensor electrical connector (4). (Scheme 7)
  6. Remove the harness clips (3) from the transfer case. (Scheme 7)
  7. Reposition the harness.
  8. Remove the vent hose. (Scheme 8)
  9. Remove the control rod. See «CONTROL ROD»(ref-155256-S06050748492003061200000).
  10. Support the transmission with a suitable transmission jack stand.
  11. Remove the transmission mount nuts. (Scheme 2)
  12. Raise the transmission slightly in order to remove the transmission support.
  13. Remove the transmission support bolts. (Scheme 3)
  14. Remove the transmission support.
  15. Support the transfer case with a suitable jack stand.
  16. Remove the transmission mount bolts. (Scheme 9)
  17. Remove the transmission mount. (Scheme 10)
  18. Remove the transfer case adapter nuts. (Scheme 11)
  19. Remove the shift control switch harness bracket. NOTE: The following service procedure must be performed with the assistance from another technician.
  20. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle. (Scheme 4)
  21. Rotate the transfer case so that the front output shaft is above the torsion bar bracket.
  22. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket.
  23. Lower the transfer case.

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Installation (NVG 261)

  1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
  2. Rotate the transfer case so that it is in line with the adapter.
  3. Install the transfer case. (Scheme 4)
  4. Install the shift control switch harness bracket.
  5. Install the transfer case adapter nuts. (Scheme 11) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  6. Install the transmission mount. (Scheme 10)
  7. Install the transmission mount bolts. (Scheme 9) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  8. Install the crossmember.
  9. Install the crossmember bolts. (Scheme 3) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  10. Lower the transfer case and transmission onto the transmission support.
  11. Install the transmission mount nuts. (Scheme 2) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  12. Remove the support from the transfer case.
  13. Remove the transmission jack stand.
  14. Install the control rod. See «CONTROL ROD»(ref-155256-S06050748492003061200000).
  15. Install the vent hose. (Scheme 8)
  16. Position the harness.
  17. Install the harness clips (3) to the transfer case. (Scheme 7)
  18. Connect the speed sensor electrical connector (4). (Scheme 7)
  19. Connect the gear indicator switch electrical connector (2). (Scheme 7)
  20. Install the in-line to engine harness electrical connector (1) to the bracket. (Scheme 7)
  21. Install the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  22. Check the fluid level. See LUBRICATION in appropriate SERVICING article. Add fluid if necessary.
  23. Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).

Removal (NVG 263)

  1. Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).
  2. Drain the transfer case fluid. See LUBRICATION in appropriate SERVICING article.
  3. Remove the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  4. Remove the transmission shift control cable clip from the transfer case. (Scheme 12)
  5. Remove the transmission vent hose clip from the bracket, if equipped.
  6. Disconnect the speed sensor electrical connector. (Scheme 13)
  7. Disconnect the in-line to engine harness electrical connector.
  8. Remove the in-line connector from the harness bracket.
  9. Disconnect the encoder motor electrical connector.
  10. Remove the clips from the transfer case brackets.
  11. Disconnect the transfer case vent hose. (Scheme 8)
  12. Support the transmission with a suitable transmission jack stand.
  13. Remove the transmission mount nuts. (Scheme 2)
  14. Remove the crossmember bolts. (Scheme 3)
  15. Remove the crossmember.
  16. Remove the transmission mount bolts. (Scheme 9)
  17. Remove the transmission mount from the adapter.
  18. Support the transfer case with a suitable jack stand.
  19. Remove the transfer case adapter nuts. (Scheme 11)
  20. Remove the harness bracket. NOTE: The following service procedure must be performed with the assistance from another technician.
  21. Remove the transfer case, perform the following: Slide the transfer case straight back toward the rear of the vehicle. Rotate the transfer case so that the front output shaft is above the torsion bar bracket. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket. Lower the transfer case.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Installation (NVG 263)

Note. The following installation procedure must be performed with the assistance of another technician.

  1. Install the transfer case, perform the following: Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket). Rotate the transfer case so that it is in line with the adapter. Install the transfer case to the adapter.
  2. Install the transfer case adapter nuts. (Scheme 11) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  3. Install the transmission mount.
  4. Install the transmission mount bolts. (Scheme 9) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  5. Install the crossmember.
  6. Install the crossmember bolts. (Scheme 3) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  7. Lower the transmission/transfer case.
  8. Install the transmission mount nuts. (Scheme 2) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  9. Remove the transmission jack stand.
  10. Connect the transfer case vent hose. (Scheme 8)
  11. Install the clips to the transfer case brackets.
  12. Connect the encoder motor electrical connector.
  13. Install the in-line connector to the harness bracket.
  14. Connect the in-line to engine harness electrical connector.
  15. Connect the speed sensor electrical connector. (Scheme 13)
  16. Install the transmission vent hose clip to the bracket, if equipped.
  17. Install the transmission shift control cable clip to the transfer case. (Scheme 12)
  18. Install the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  19. Fill transfer case with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING article. Add fluid if necessary.
  20. Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).

Note. Before beginning the following service procedure, place automatic transmission equipped vehicles into the Park position. Place manual transmission equipped vehicles into first gear. Then place the transfer case in the 2 HI position.

  1. Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).
  2. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Remove the control rod from the control lever. (Scheme 15)
  4. Remove the control rod from the shift lever. (Scheme 16)
  5. Remove the control rod.

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Note. Before installing a NEW control rod, loosen the adjusting bolt on the control rod so it slides with slight resistance. (Scheme 17) When installing the control rod on the control levers, a snapping sound should be heard or felt upon installation.

  1. Install the control rod onto the control lever first. (Scheme 15)
  2. Slide the control rod forward.
  3. Install the control rod onto the shift control lever. (Scheme 16)
  4. Tighten the control rod adjusting bolt to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  5. Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  6. Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155256-S33493596412003061100000).

Scheme 17

Scheme 17
Scheme 17
  1. Raise and suitably support the vehicle.
  2. Remove the transfer case shield bolts and remove the transfer case shield. (Scheme 18)

Scheme 18

Scheme 18
Scheme 18
  1. Position the transfer case shield and install the transfer case shield bolts. (Scheme 18) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155256-S09180942812003061100000).
  2. Lower the vehicle.

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