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Transfer Case - Servicing: Removal & Installation Chevrolet TrailBlazer I

Transfer Case 15 illustrations ~572 words

REMOVAL & INSTALLATION

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 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.

Removal

  1. Raise the vehicle.
  2. Remove the fuel tank shield, if equipped. See «FUEL TANK SHIELD»(ref-155255-S08708319192003061100000) under REMOVAL & INSTALLATION in REMOVAL & INSTALLATION - BRAVADA, ENVOY, ENVOY XL & TRAILBLAZER article.
  3. Remove the transfer case shield as follows, if equipped: Remove the transfer case shield mounting bolts (3) from the transmission support. see scheme 2 Remove the transfer case shield (2) from transmission support.
  4. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Remove the dust shield from the front output shaft. (Scheme 1)
  6. Lightly tap the screw driver around the edge of the front output shaft seal. (Scheme 2)
  7. Pry the front output shaft seal from the transfer case. (Scheme 3)
  8. Remove the front output shaft seal from the transfer case. (Scheme 4)

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

  1. Install the output shaft seal installer on the front output shaft. (Scheme 5)
  2. Align the front output shaft seal on the output shaft seal installer (1). (Scheme 6)
  3. Using the output shaft seal installer (2), install the front output shaft seal. (Scheme 6)
  4. Remove the output shaft seal installer.
  5. Install the dust shield on the front output shaft. (Scheme 1)
  6. Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  7. Inspect the transfer case fluid level. See «LUBRICATION»(ref-155057-S12468121692003060500000).
  8. Install the transfer case shield as follows, if equipped: Install the transfer case shield (2) to the transmission support. Ensure that the J-nuts (1) are in place. see scheme 2 Install the transfer case shield mounting bolts (3). Tighten the transfer case shield mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155057-S21515925542003060500000).
  9. Install the fuel tank shield, if equipped. See «FUEL TANK SHIELD»(ref-155255-S08708319192003061100000) under REMOVAL & INSTALLATION in REMOVAL & INSTALLATION - BRAVADA, ENVOY, ENVOY XL & TRAILBLAZER article.
  10. Lower the vehicle.

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. Raise the vehicle.
  2. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Remove the rear output shaft seal. (Scheme 7)
  4. Inspect the rear output shaft bushing for scoring or wear.
  5. Remove the rear output shaft bushing, if required, using the rear bushing remover/installer as follows: Install the finger section of the rear bushing remover/installer in front of the bushing. (Scheme 8) Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. Using a wrench on the forcing screw, remove the rear output shaft bushing.

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Using the rear bushing remover/installer, install a NEW output shaft bushing as follows: Install the bushing or the finger section of the rear bushing remover/installer. (Scheme 9) Install the finger section to the main body of the rear bushing remover/installer. Position the bushing and tool to the case. Using a hammer and the rear bushing remover/installer, install the bushing.
  2. Align the rear output shaft seal. (Scheme 10)
  3. Using the output shaft seal installer and hammer, install the rear output shaft seal. (Scheme 11)
  4. Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Inspect the transfer case fluid level. See «LUBRICATION»(ref-155057-S12468121692003060500000).
  6. Lower the vehicle.

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Note. Speed sensors removal and installation is an unbolt and bolt on procedure. For speed sensor and electrical connectors location (Scheme 12)- (Scheme 15). For speed sensors tightening specifications, see TORQUE SPECIFICATIONS.

Scheme 12

Scheme 12: Removal & Installation
Scheme 12: Removal & Installation

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

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