GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Chevy K Silverado - 4WD 🢒 General Information 🢒 General Information 🢒 Transfer Case Adapter Replacement

Removal Procedure

    Object Number: 648037 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the transfer case from the vehicle. Refer to Transfer Case Assembly Replacement .
  3. Support the transmission with a suitable jack stand.

    4. Object Number: 652595 Size: SH
  4. Remove the rear crossmember from the frame.

    5. Object Number: 652614 Size: SH
  5. Remove the mounting bolts from the adapter to the transmission.
  6. Remove the adapter from the transmission (automatic shown).
  7. Remove the seal between the transfer case and the adapter.

    8. Object Number: 654219 Size: SH
  8. Remove the gasket from the adapter.

Installation Procedure

    Object Number: 652614 Size: SH

    Important: Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal.

  1. Install the new seal on the adapter.

    2. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.

  2. Install the adapter to the transmission.

    3. Object Number: 648011 Size: SH

    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 adapter mounting bolts to the transmission.

    4. Tighten
    Tighten the mounting bolts to 50 N·m (36 lb ft).


    Object Number: 654219 Size: SH

    Important: When installing the gasket to the adapter, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing up.

  4. Install the new gasket to the adapter.

    5. Object Number: 648037 Size: SH
  5. Install the transfer case to the adapter. Refer to Transfer Case Assembly Replacement .

    6. Object Number: 652595 Size: SH
  6. Install the crossmember in the vehicle.

    7. Tighten
    Tighten the mounting bolts to 70 N·m (51 lb ft).

  7. Remove the transmission jack from the transmission.
  8. Check the fluid level of the transfer case. Refer to Transfer Case Fluid Replacement .
  9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.