GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 GMC K Sierra - 4WD 🢒 General Information 🢒 General Information 🢒 Transfer Case Assembly Replacement

Removal Procedure

    Object Number: 396828 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the transfer case shield. Refer to Transfer Case Shield Replacement.
  3. Drain the transfer case of fluid. Refer to Transfer Case Fluid Replacement.
  4. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement.
  5. Remove the rear propeller shaft.
    6. • For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement.
    • For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement.

    Object Number: 662044 Size: SH
  6. Remove the transfer case gear indicator switch electrical connector.
  7. Remove the transfer case speed sensor electrical connector.
  8. Remove the transfer case control rod from the transfer case. Refer to Transfer Case Control Rod Replacement.

    9. Object Number: 715667 Size: SH
  9. Remove the transfer case vent hose.
  10. Support the transmission with a suitable transmission jack stand.

    11. Object Number: 647997 Size: SH
  11. Remove the transmission mount retaining nuts.
  12. Raise the transmission high enough in order to remove the transmission support
  13. Remove the transmission support mounting bolts.

    14. Object Number: 652595 Size: SH
  14. Remove the transmission support from the frame.
  15. Support the transfer case with a suitable jack stand.

    16. Object Number: 715661 Size: SH
  16. Remove the transmission mount bolts.

    17. Object Number: 648001 Size: SH
  17. Remove the transmission mount assembly.

    18. Object Number: 715663 Size: SH
  18. Remove the transfer case adapter retaining nuts.
  19. Remove the support for the transfer case.

    20. Important: The following service procedure must be performed with the assistance from another technician.

  20. Slide the transfer case straight back toward the rear of the vehicle.
  21. Rotate the transfer case so that the front output shaft is above the torsion bar bracket.
  22. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket.
  23. Lower the transfer case.

Installation Procedure
  1. Apply GM /P/N 12345879 (Canadian P/N 10953511) or equivalent lubricant, meeting GM Specification 9985830 to the input shaft splines.

    2. Object Number: 715663 Size: SH

    Important: The following installation procedure must be performed with the assistance of another technician.

  2. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
  3. Rotate the transfer case so that it is in line with the transfer case adapter.
  4. Install the transfer case to the transfer case adapter.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the transfer case retaining nuts.

    6. Tighten
    Tighten the transfer case retaining nuts to 50 N·m (36 lb ft).

  6. Support the transfer case with a suitable jack stand.

    7. Object Number: 648001 Size: SH
  7. Install the transmission mount assembly.

    8. Object Number: 715661 Size: SH
  8. Install the transmission mount bolts.

    9. Tighten
    Tighten the transmission mount bolts to 47 N·m (34 lb ft).


    Object Number: 652595 Size: SH
  9. Install the transmission support to the frame.
  10. Install the transmission support mounting bolts.

    11. Tighten
    Tighten the transmission support mounting bolts to 70 N·m (51 lb ft).


    Object Number: 647997 Size: SH
  11. Lower the transfer case and transmission assembly on the transmission support.
  12. Install the transmission mount retaining nuts.

    13. Tighten
    Tighten the transmission mount retaining nuts to 40 N·m (29 lb ft).

  13. Remove the support from the transfer case.
  14. Remove the transmission jack stand.

    15. Object Number: 662044 Size: SH
  15. Install the transfer case gear indicator switch electrical connector.
  16. Install the transfer case speed sensor electrical connector.
  17. Install the transfer case control rod. Refer to Transfer Case Control Rod Replacement.

    18. Object Number: 715667 Size: SH
  18. Install the transfer case vent hose.
  19. Install the rear propeller shaft.
    20. • For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement.
    • For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement.
  20. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement.
  21. Fill the transfer case with the approved fluid. Refer to Transfer Case Fluid Replacement.
  22. Install the transfer case shield to the transmission support. Refer to Transfer Case Speed Sensor Replacement.
  23. Lower the vehicle. Refer to Lifting and Jacking the Vehicle.