Transfer Case - Servicing: Removal & Installation GMC Savana H2500

REMOVAL & INSTALLATION

Scheme 7

1. Raise the vehicle.
2. Remove the transfer case from the vehicle. Refer to «TRANSFER CASE»(ref-155137-S30354992932003060900000).
3. Remove the mounting bolts from the adapter to the transmission. (Scheme 7)
4. Remove the adapter from the transmission.
5. Remove the seal between the transfer case and the adapter.
6. Remove the transfer case to the adapter gasket.

Installation Procedure

Note. Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal.

1. Install the new seal on the adapter. (Scheme 7) NOTE: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.
2. Install the adapter to the transmission. CAUTION: Use 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.
3. Install the adapter mounting bolts to the transmission. Tighten Tighten the mounting bolts to 50 N.m (37 lb ft). NOTE: The locating tab on the gasket should always be pointing up
4. Install the new gasket to the adapter.
5. Install the transfer case to the adapter. Refer to «TRANSFER CASE»(ref-155137-S30354992932003060900000).
6. Install the transmission support member. Refer to TRANSMISSION SUPPORT REPLACEMENT in FRAME AND UNDERBODY.
7. Remove the transmission jack from the transmission.
8. Check the fluid level of the transfer case. Refer to «DRAINING & REFILLING»(ref-155005-S18754532662003060400000).
9. Lower the vehicle.

Removal Procedure

Scheme 8

1. Raise the vehicle.
2. Remove the transfer case from the adapter. Refer to «TRANSFER CASE»(ref-155137-S30354992932003060900000).
3. Using the J 36825 (2) and J 23907 (1) remove the input shaft seal. (Scheme 8) Poke a hole in the seal using a very small punch. Thread the tool J 36825 (2) into the hole.

Removal

1. Raise the vehicle.
2. Remove the front propeller shaft from the vehicle. See «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-170201-S20324735932005010500000).
3. Insert a flat-tipped screw driver in the inner race. (Scheme 9) Pry the inner race forward.
4. Insert a small pry bar in the inner race. Pry the inner part of the seal from the outer seal body. Remove the inner part of the seal. (Scheme 10)
5. Insert a flat-tipped screw driver or small pry bar in the space between the outer race of the seal and the transfer case. Pry the outer race out of the transfer case. Remove the outer part of the seal. (Scheme 11)

Scheme 9

Scheme 10

Scheme 11

Installation

1. Using the front output shaft seal installer (2) and the universal handle (1), install the transfer case output seal. (Scheme 12)
2. Install the front propeller shaft. See «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-170201-S20324735932005010500000).
3. Check the transfer case fluid level. See «DRAINING & REFILLING»(ref-155005-S18754532662003060400000).
4. Lower the vehicle.

Scheme 12

1. Raise and suitably support the vehicle.
2. Remove the rear propeller shaft. See «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-170201-S17003667172005010500000).
3. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver. (Scheme 13)
4. To install, use rear output shaft seal installer and install a NEW rear output shaft seal. (Scheme 14)
5. Install the rear propeller shaft. See «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-170201-S17003667172005010500000).
6. Check the fluid level. See «CHECKING FLUID LEVELS»(ref-155005-S34522647512003060400000). Add fluid, if necessary.
7. Lower the vehicle.

Scheme 13

Scheme 14

1. Raise the vehicle.
2. Remove the electrical connector from the speed sensor. (Scheme 15)
3. Remove the speed sensor and the "O" ring from the transfer case. (Scheme 16)
4. Install the NEW speed sensor into the transfer case with a NEW "O" ring seal. (Scheme 16) Tighten the right rear speed sensor to specification. See «TORQUE SPECIFICATIONS»(ref-155005-S11503406252003060400000).
5. Install the electrical connector to the speed sensor. (Scheme 15)
6. Lower the vehicle.

Scheme 15

Scheme 16