GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2005 🢒 Ascender - 4WD 🢒 Preface 🢒 Cautions and Notices 🢒 Transfer Case Assembly Replacement

Removal Procedure

  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement .
  3. Drain the transfer case. Refer to Transfer Case Fluid Replacement .

    4. Object Number: 747098 Size: SH
  4. Remove the fuel lines from the retainer.

    5. Object Number: 747099 Size: SH
  5. Remove the electrical harness from the retainer (right side).

    6. Object Number: 747096 Size: SH
  6. Remove the electrical harness from the retainer (left side).

    7. Object Number: 746670 Size: SH
  7. Disconnect the electrical connectors from the speed sensors (front speed sensor shown).
  8. Disconnect the motor/encoder electrical connector.

    9. Object Number: 747103 Size: SH
  9. Remove the transfer case wiring harness.

    10. Object Number: 747097 Size: SH
  10. Disconnect the vent hose.
  11. Install a transmission jack for the transfer case.

    12. Object Number: 879658 Size: SH
  12. Remove the transfer case adapter (2) to transfer case nuts (5).

    13. Important: While removing the transfer case the front propeller shaft must be disconnected from the transfer case. Refer to Front Propeller Shaft Replacement .

  13. Remove the transfer case (3) from the vehicle.

    14. Important: The transfer case gasket may become damaged during the removal procedure.

  14. Remove the transfer case gasket (4).

Installation Procedure

    Object Number: 879658 Size: SH

    Important: If the transfer case gasket is damaged, replace it. DO NOT use silicone sealant in place or with the transfer case gasket.

    Important: While installing the transfer case the front propeller shaft must be connected to the transfer case. Refer to Front Propeller Shaft Replacement .

  1. Install or replace the transfer case gasket (4).
  2. Install the transfer case (3) in the vehicle.

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

  3. Install the transfer case adapter (2) to transfer case nuts (5). Ensure the fuel line retainer (1) is in place.

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

  4. Remove the transmission jack stand.

    5. Object Number: 746670 Size: SH
  5. Connect the electrical connectors to the speed sensors (front speed sensor shown).

    6. Object Number: 747097 Size: SH
  6. Connect the vent hose.
  7. Connect the motor/encoder electrical connector.

    8. Object Number: 747103 Size: SH
  8. Install the transfer case harness to the transfer case.

    9. Object Number: 747096 Size: SH
  9. Install the transfer case wiring harness to the retainers (left side).

    10. Object Number: 747099 Size: SH
  10. Install the transfer case wiring harness to the retainers (right side).

    11. Object Number: 747098 Size: SH
  11. Install the fuel lines to the retainer.
  12. Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement .
  13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
  14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .