GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Tracker - 4WD 🢒 Preface 🢒 Cautions and Notices 🢒 Transfer Case Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative (-) battery cable.
  2. Remove the 2 screws, the 2 plastic retainers and the rear console box from the floor.
  3. Remove the 2 screws, the 2 plastic retainers and the front console box from the floor.

    4. Object Number: 167065 Size: SH
  4. Remove the 1 screw and the transfer case gearshift control lever knob (1)  from the transfer case gearshift control lever.

    5. Object Number: 167066 Size: SH
  5. Remove the 6 screws, the boot cover and the gearshift control lever boot (1) from the gearshift control lever (2).
  6. Remove the 1 clamp and the gearshift lever case boot from the gearshift lever case.

    7. Object Number: 167096 Size: SH
  7. Remove the gearshift control lever (1) from the gearshift lever case (2) by pushing down on the gearshift control lever pivot (3) and turning counterclockwise 90 degrees, 1/4 turn, and lifting up.

    8. Object Number: 167506 Size: SH
  8. Remove the four-wheel drive switch electrical connector (1) from the four wheel drive switch (2), if equipped.

    9. Object Number: 167508 Size: SH
  9. Remove the four-wheel drive low switch electrical connector  (3) from the four-wheel drive low switch (4), if equipped.
  10. Remove the 4 bolts from the fan shroud at the radiator.
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Place a drain pan or suitable container under the transfer case.

    13. Object Number: 627867 Size: SH
  13. Remove the transfer case oil level/filler plug (1) from the transfer case.
  14. Remove the transfer case drain plug (2) from the transfer case and drain the transfer case oil.

    15. Important: An index mark should be made on the front and rear propeller shaft pinion flange yokes and the front and rear differential pinion flanges to ensure that the front and rear propeller shafts are installed in the same positions from which they were removed. If this precaution is not observed, a driveline imbalance may result causing vibration, premature component wear or other undesirable conditions.

  15. Place an index mark on the front propeller shaft pinion flange yoke and the front deferential pinion flange, if equipped.
  16. Remove the 4 bolts, the 4 nuts and the front propeller shaft from the vehicle, if equipped.
  17. Place an index mark on the rear propeller shaft pinion flange yoke and the differential pinion flange.
  18. Remove the 4 bolts, the 4 nuts and the rear propeller shaft from the vehicle.

    19. Object Number: 480289 Size: SH
  19. Remove the VSS (2) from the case.
  20. Remove the sensor harness from the crossmember.
  21. Support the transfer case with a suitable hydraulic jack.

    22. Object Number: 480323 Size: SH
  22. Remove the following components:
    23. • The 6 nuts (1,4)
    • The 6 bolts
    • The transfer case skid plate (2)
    • The 2 transfer case braces
  23. Remove the 10 bolts and the transfer case crossmember (1) from the undercarriage.
  24. Remove the 1 clamp and the breather hose from the gearshift lever case.
  25. Remove the 1 clamp and the breather hose from the cover.
  26. Remove the gearshift lever case from the rear case manual transmission equipped vehicles. Refer to Gearshift Control Lever Replacement in Manual Transmission.
  27. Remove the 12 transfer case-to-transmission bolts.
  28. Slide the transfer case off the transmission output shaft and slowly lower the transfer case making sure there are no obstructions.

Installation Procedure
  1. Raise the transfer case into position and slide it onto the transmission output shaft.

    2. 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.

  2. Install the 10  transfer case-to-transmission bolts.

    3. Tighten
    Tighten the 10 transfer case-to-transmission bolts to 28 N·m (21 lb ft).

  3. Install the breather hose to the gearshift lever case. Secure with the 1 clamp.
  4. Install the breather hose to the cover. Secure with the 1 clamp.
  5. Install the gearshift lever case to the rear case manual transmission equipped vehicles.

    6. Object Number: 480323 Size: SH
  6. Install the transfer case crossmember (1) to the undercarriage. Secure the crossmember with the 6 bolts (3).

    7. Tighten
    Tighten the transfer case crossmember bolts to 50 N·m (37 lb ft).

  7. Install the following:
    8. • The skid plate (2)
    • The 2 transfer case braces
  8. Secure the skid plate and the 2 braces with the 6 nuts and the bolts (1,4).

    9. Tighten
    Tighten the transfer case skid plate bolts and the nuts to 50 N·m (37 lb ft).

  9. Remove the hydraulic jack from under the transfer case.
  10. Install the sensor harness to the crossmember.
  11. Install the ground wire and bolt.
  12. Install the rear propeller shaft into the vehicle aligning the reference marks made during the removal. Secure the rear propeller shaft with the 4 bolts and 4 nuts.

    13. Tighten
    Tighten the rear propeller shaft bolts and nuts to 50 N·m (37 lb ft).

  13. Install the front propeller shaft into the vehicle aligning the reference marks made during removal. Secure the front propeller shaft the 4 bolts and the 4 nuts, if equipped.

    14. Tighten
    Tighten the front propeller shaft bolts and nuts to 50 N·m (37 lb ft).

  14. Apply GM P/N 12346004 or the equivalent, to the threaded portion of the transfer case drain plug.

    15. Object Number: 480289 Size: SH
  15. Connect the VSS (2) to the case.

    16. Object Number: 627867 Size: SH
  16. Install the transfer case drain plug (2) into the transfer case.

    17. Tighten
    Tighten the transfer case drain plug to 28 N·m (21 lb ft).

  17. Add approximately 1.7 liters (1.8 qts) of 75W-90 GL4 lubricant, or the equivalent, into the transfer case oil level/filler plug hole. The oil level should be even with the bottom of the oil level/filler plug (1).
  18. Apply GM P/N 12346004 (Canadian P/N 10953480), or the equivalent, to the threaded portion of the transfer case oil level/filler plug (1).
  19. Install the transfer case oil level/filer plug (1) into the transfer case.

    20. Tighten
    Tighten the transfer case oil level/filler plug (1) to 28 N·m (21 lb ft).

  20. Lower the vehicle.
  21. Install the 4 bolts to the fan shroud at the radiator.

    22. Tighten
    Tighten the fan shroud bolt to 10 N·m (89 lb in).


    Object Number: 167508 Size: SH
  22. Connect the four-wheel drive switch electrical connector (2) to the four-wheel drive switch (1).
  23. Install the four-wheel drive low switch electrical connector (3) to the four-wheel drive low switch (4).
  24. Install the gearshift control lever. Refer to Shift Lever Replacement - On Vehicle .
  25. Connect the negative battery cable.