GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Chevy K Pickup - 4WD 🢒 Driveline/Axle 🢒 Transfer Case - BW 4401 (Two Speed Manual) 🢒 Transfer Case Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the transfer case shield. Refer to Shield Replacement .
  3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement or Three-Piece Propeller Shaft Replacement in Propeller Shaft.
  4. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.

    5. Object Number: 175384 Size: SH
  5. Disconnect the vehicle speed sensor electrical connector.
  6. Disconnect the wiring harness from the transfer case.

    7. Object Number: 1313 Size: SH
  7. Disconnect the transfer case shift cable at the transfer case. Refer to Shift Cable Replacement .

    8. Support the transfer case with a jack.


    Object Number: 175406 Size: SH
  8. Remove the bolts securing the transfer case to the transmission adapter.
  9. Remove the gasket.

    10. Object Number: 2214 Size: SH
  10. Discard the gasket.

Installation Procedure

    Object Number: 2214 Size: SH
  1. Install a new gasket to the transmission. Use sealer GM P/N 12346004 in order to hold the gasket in place.

    2. Object Number: 175406 Size: SH
  2. Install the transfer case to the transmission adapter.

    3. Notice: 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 bolts that secure the transfer case to the transmission adapter.

    4. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).

  4. Remove the jack from the transfer case.
  5. Install the transfer case shift linkage at the transfer case.
  6. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
  7. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement or Three-Piece Propeller Shaft Replacement in Propeller Shaft.
  8. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  9. Install the transfer case shield. Refer to Shield Replacement .
  10. Check the transfer case lubricant level. Add oil as necessary. Refer to Capacities - Approximate Fluid .
  11. Lower the vehicle.