GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Yukon XL - 4WD 🢒 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 shields. Refer to Transfer Case Shield Replacement .
  3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  4. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement in Propeller Shaft.

    5. Object Number: 715660 Size: SH
  5. Disconnect the motor/encoder electrical connector.

    6. Object Number: 715667 Size: SH
  6. Remove the transfer case vent hose.

    7. Object Number: 647994 Size: SH
  7. Remove the electrical wiring harness from the transfer case.

    8. Important: Ensure that the transfer case is correctly secured to the transmission jack.

  8. Support the transfer case with a suitable transmission jack.

    9. Object Number: 715663 Size: SH

    Important: When removing the transfer case from the transmission, do not remove the transmission mount or the transfer case adapter.

  9. Remove the transfer case retaining nuts from the transfer case studs.

    10. Object Number: 715726 Size: SH
  10. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle.
  11. Rotate the transfer case so that the transfer case is perpendicular to the transmission assembly.
  12. Lower the transfer case.

Installation Procedure

    Object Number: 715726 Size: SH
  1. Rotate the transfer case so that the transfer case is perpendicular to the transmission assembly.
  2. Raise the transfer case into position.
  3. Rotate the transfer case so that the transfer case aligns with the transfer case adapter.
  4. Install the transfer case assembly.

    5. Object Number: 715663 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.

  5. Install the transfer case retaining nuts.

    6. Tighten
    Tighten the transfer case retaining nuts to 50 N·m (37 lb ft).


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

    7. Object Number: 647994 Size: SH
  7. Install the electrical wiring harness to the transfer case.

    8. Object Number: 715660 Size: SH
  8. Connect the motor/encoder electrical connector.
  9. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  10. Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement in Propeller Shaft.
  11. Inspect the transfer case fluid level. Refer to Transfer Case Fluid Replacement .

    12. Object Number: 396828 Size: SH
  12. Install the transfer case shield. Refer to Transfer Case Shield Replacement .
  13. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.