GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 GMC C Sierra - 2WD 🢒 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 in General Information.
  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 in Propeller Shaft.
  5. Remove the rear propeller shaft.
    6. • For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement in Propeller shaft.
    • For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft.

    Object Number: 102222 Size: SH
  6. Remove the transmission shift control cable from the transfer case.

    7. Object Number: 662044 Size: SH
  7. Remove the transfer case speed sensor electrical connector.

    8. Object Number: 715660 Size: SH
  8. Remove the motor/encoder electrical connector.

    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 mount.

    13. Object Number: 652595 Size: SH
  13. Remove the transmission support mounting bolts.
  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. Remove the transmission mount from the adapter.

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

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

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

Installation Procedure

    Object Number: 715663 Size: SH

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

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

    4. 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.

  4. Install the transfer case retaining nuts.

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


    Object Number: 715661 Size: SH
  5. Install the transmission mount assembly.
  6. Install the transmission mount bolts.

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


    Object Number: 652595 Size: SH
  7. Install the transmission support to the frame.
  8. Install the transmission support mounting bolts.

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


    Object Number: 647997 Size: SH
  9. Lower the transmission/transfer case assembly to the transmission support.
  10. Install the transmission mount retaining nuts.

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

  11. Remove the transmission jack stand.

    12. Object Number: 662044 Size: SH
  12. Install the transfer case speed sensor electrical connector.

    13. Object Number: 715660 Size: SH
  13. Install the electrical connector to the motor/encoder.

    14. Object Number: 715667 Size: SH
  14. Install the transfer case vent hose.

    15. Object Number: 102222 Size: SH
  15. Install the transmission shift control cable to the transfer case.
  16. Install the rear propeller shaft.
    17. • For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement in Propeller shaft.
    • For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft.
  17. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  18. Fill the transfer case with the approved fluid. Refer to Transfer Case Fluid Replacement .
  19. Install the transfer case shield. Refer to Transfer Case Shield Replacement .
  20. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.