GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Jimmy - 4WD 🢒 General Information 🢒 General Information 🢒 Transfer Case Replacement

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
  2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or to Two-Piece Propeller Shaft Replacement in Propeller Shaft.

    4. Object Number: 416724 Size: SH
  4. Remove the vent hose from the transfer case.
  5. Disconnect the vehicle speed sensor electrical connectors.
  6. Remove the electrical connectors from the transfer case motor/encoder.
  7. Remove any wiring harness from the transfer case.
  8. Support the transfer case with a transmission jack.

    9. Object Number: 33202 Size: SH
  9. If equipped with a manual transmission, remove the bolt securing the left side support brace to the transmission.

    10. Object Number: 33180 Size: SH
  10. If equipped with a manual transmission, remove the bolt and stud securing the left side support brace to the transfer case.

    11. Object Number: 33146 Size: SH
  11. If equipped with a manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case.

    12. Object Number: 396825 Size: SH
  12. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission.
  13. Remove the transfer case.
    14. • Start by pulling the transfer case straight back from the transmission.
    • After the transfer case is pulled out from the transmission turn and lower the transfer case.

    Object Number: 396826 Size: SH
  14. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adaptor.
  15. Remove the transfer case.
    16. • Start by pulling the transfer case straight back from the transmission.
    • After the transfer case is pulled out from the transmission turn and lower the transfer case.
  16. Remove and discard the gasket.

Installation Procedure
  1. Install a new gasket to the transmission. Use sealer GM P/N 12346004 in order to hold the gasket in place.
  2. Raise and position the transfer case to the vehicle

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


    Object Number: 396826 Size: SH
  3. For vehicles equipped with a automatic transmission, install the six nuts securing the transfer case and bracket to the transmission adaptor.

    4. Tighten
    Tighten the nuts to 47 N·m (35 lb ft).


    Object Number: 396825 Size: SH
  4. For vehicles equipped with a manual transmission, install the six nuts securing the transfer case and bracket to the transmission.

    5. Tighten
    Tighten the nuts to 47 N·m (35 lb ft).


    Object Number: 33202 Size: SH
  5. If equipped with a manual transmission, install the bolt securing the left side support brace to the transmission.

    6. Tighten
    Tighten the bolt to 47 N·m (35 lb ft).


    Object Number: 33180 Size: SH
  6. If equipped with a manual transmission, install the bolt and stud securing the left side support brace to the transfer case.

    7. Tighten
    Tighten the bolt and stud to 47 N·m (35 lb ft).


    Object Number: 33146 Size: SH
  7. If equipped with a manual transmission, install the two bolts securing the right side support brace to the transmission and transfer case.

    8. Tighten
    Tighten the bolts to 47 N·m (35 lb ft).


    Object Number: 416724 Size: SH
  8. Install the vent hose to the transfer case.
  9. Inspect the transfer case oil level. Refer to Oil Replacement
  10. Connect the speed sensor electrical connectors.
  11. Install the electrical connectors to the transfer case motor/encoder.
  12. Install any wiring harness to the transfer case.
  13. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or to Two-Piece Propeller Shaft Replacement in Propeller Shaft.
  14. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  15. Lower the vehicle.