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Transfer Case - Removal & Installation: Application Chevrolet TrailBlazer I

Transfer Case 9 illustrations ~723 words

APPLICATION

ApplicationTransfer Case Model (RPO Code)
Bravada (Full-Time)NVG 126 (NP4)
Envoy, Envoy XL & TrailBlazer
AutomaticNVG 226 (NP8)
Full-TimeNVG 126 (NP4)

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.
  1. Raise the vehicle.
  2. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Drain the transfer case. See appropriate SERVICING article.
  4. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Remove the fuel lines from the retainer. (Scheme 19)
  6. Remove the right and left side electrical harness from the retainer. (Scheme 20)and (Scheme 21).
  7. Disconnect the electrical connectors from the speed sensors. (Scheme 22)
  8. Disconnect the motor/encoder electrical connector.
  9. Remove the transfer case wiring harness. (Scheme 23)
  10. Disconnect the vent hose. (Scheme 24)
  11. Install a transmission jack for the transfer case.
  12. Remove the transfer case adapter (2) to transfer case nuts (5). (Scheme 25)
  13. Remove the transfer case (3) from the vehicle. CAUTION: The transfer case gasket may become damaged during the removal procedure.
  14. Remove the transfer case gasket (4).

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25
CAUTIONIf the transfer case gasket is damaged, replace it. DO NOT use silicone sealant in place or with the transfer case gasket.
  1. Install or replace the transfer case gasket (4).
  2. Install the transfer case (3) in the vehicle.
  3. Install the transfer case adapter (2) to transfer case nuts (5). Ensure the fuel line retainer (1) is in place. (Scheme 25) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155255-S34118634182003061100000).
  4. Remove the transmission jack stand.
  5. Connect the electrical connectors to the speed sensors. (Scheme 22)
  6. Connect the vent hose. (Scheme 24)
  7. Connect the motor/encoder electrical connector.
  8. Install the transfer case harness to the transfer case. (Scheme 23)
  9. Install the transfer case wiring harness to the retainers right and left side. (Scheme 20)and (Scheme 21).
  10. Install the fuel lines to the retainer. (Scheme 19)
  11. Install the front and rear drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  12. Fill the transfer case with appropriate fluid to proper level. See appropriate SERVICING article.
  13. Lower the vehicle.
  1. Raise the vehicle.
  2. Remove the fuel tank shield, if equipped. See «FUEL TANK SHIELD»(ref-155255-S08708319192003061100000).
  3. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS in article DRIVELINE/AXLES.
  4. Drain the transfer case. See appropriate SERVICING article.
  5. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  6. Remove the fuel lines from the retainer. (Scheme 19)
  7. Remove the electrical harness from the retainer right and left side. (Scheme 20)and (Scheme 21).
  8. Disconnect the electrical connectors from the speed sensors. (Scheme 22)
  9. Disconnect the motor/encoder electrical connector.
  10. Remove the transfer case wiring harness. (Scheme 23)
  11. Disconnect the vent hose. (Scheme 24)
  12. Install a transmission jack for the transfer case.
  13. Remove the transfer case adapter (2) to transfer case nuts (5). (Scheme 25)
  14. Remove the transfer case (3) from the vehicle. CAUTION: The transfer case gasket may become damaged during the removal procedure.
  15. Remove the transfer case gasket (4).
CAUTIONIf the transfer case gasket is damaged, replace it. DO NOT use silicone sealant in place or with the transfer case gasket.
  1. Install or replace the transfer case gasket (4).
  2. Install the transfer case (3) in the vehicle.
  3. Install the transfer case adapter (2) to transfer case nuts (5). Ensure the fuel line retainer (1) is in place. (Scheme 25) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-155255-S34118634182003061100000).
  4. Remove the transmission jack stand.
  5. Connect the electrical connectors to the speed sensors. (Scheme 22)
  6. Connect the vent hose. (Scheme 24)
  7. Connect the motor/encoder electrical connector.
  8. Install the transfer case harness to the transfer case. (Scheme 23)
  9. Install the transfer case wiring harness to the retainers right and left side. (Scheme 20)and (Scheme 21).
  10. Install the fuel lines to the retainer. (Scheme 19)
  11. Install the rear and front drive shafts. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  12. Fill the transfer case with appropriate fluid to proper level. See appropriate SERVICING article.
  13. Install the fuel tank shield, if equipped. See «FUEL TANK SHIELD»(ref-155255-S08708319192003061100000).
  14. Lower the vehicle.
  1. Raise and support the vehicle.
  2. Remove the frame brace mounting bolts. (Scheme 26)
  3. Remove the frame brace.
  4. Remove the fuel tank shield to the frame retaining bolts and nut. (Scheme 27)
  5. Remove the fuel tank shield from the frame.

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Install the fuel tank shield to the frame.
  2. Install the fuel tank shield to the frame retaining bolts and nut. (Scheme 27) Tighten the fuel tank shield to the frame retaining bolts and nut to specification. See «TORQUE SPECIFICATIONS»(ref-155255-S34118634182003061100000).
  3. Install the frame brace.
  4. Install the frame brace mounting bolts. (Scheme 26) Tighten the frame brace mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155255-S34118634182003061100000).
  5. Lower the vehicle.

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