GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series Commercial (Cutaway) C6/C7/C8 🢒 Driveline/Axle 🢒 Transfer Case - NVG 273 🢒 Transfer Case Replacement

Removal Procedure
  1. Remove the transfer case shield. Refer to Transfer Case Shield Replacement .
  2. Drain the transfer case of fluid.
  3. Remove the front propeller shafts. Refer to Front Propeller Shaft Replacement .
  4. Remove the rear propeller shaft. Refer to One-Piece Rear Propeller Shaft Replacement or Two-Piece Rear Propeller Shaft Replacement .
  5. Remove the transmission vent hose clip from the transfer case.

    6. Object Number: 1388287 Size: SH
  6. Disconnect the transfer case actuator electrical connector.
  7. Support the transmission with a suitable transmission jack stand.

    8. Object Number: 1388284 Size: SH
  8. Remove the front transfer case mount bolts.

    9. Object Number: 1388280 Size: SH
  9. Remove the side transfer case mount nuts and bolts.

    10. Object Number: 1388284 Size: SH
  10. Remove the rear transfer case mount nuts and bolts.

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

  11. Remove the transfer case from the front, side and rear transfer case mounts.

Installation Procedure

    Object Number: 1388284 Size: SH
  1. Position the transfer case into the front, side and rear transfer case mounts.
  2. Install all transfer case mounting fasteners prior to tightening.

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

  3. Install the front transfer case mount bolts.

    4. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).


    Object Number: 1388280 Size: SH
  4. Install the side transfer case mount bolts and nuts.

    5. Tighten
    Tighten the nuts to 110 N·m (81 lb ft).


    Object Number: 1388284 Size: SH
  5. Install the rear transfer case bolts and nuts.

    6. Tighten
    Tighten the nuts to 110 N·m (81 lb ft).

  6. Lower the transmission/transfer case.
  7. Remove the transmission jack stand.
  8. Connect the transfer case vent hose.

    9. Object Number: 1388287 Size: SH
  9. Connect the transfer case actuator electrical connector.
  10. Install the rear propeller shaft. Refer to One-Piece Rear Propeller Shaft Replacement or Two-Piece Rear Propeller Shaft Replacement .
  11. Install the front propeller shaft(s) refer to Front Propeller Shaft Replacement .
  12. Fill the transfer case with fluid.
  13. Install the transfer case shield. Refer to Transfer Case Shield Replacement .