Installation Procedure

IMPORTANT: The front propeller shaft must be lines up with the front output shaft at the same time that the input is being slid onto the transmission output shaft and the dowel pins are engaged. The front propeller shaft is too long and can not be installed after the transfer case mounting face is bolted in place to the transmission. The transfer case needs to be loose and slid back slightly so that the cone shape of the constant velocity (CV) joint can be engaged into the front output shaft.

Fig 1: View Of Transfer Case

Courtesy of GENERAL MOTORS CORP.

Apply grease GM P/N 1051344 (Canadian P/N 993037), or equivalent, on the input splines starting from the front edge to 10 mm inward in a continuous pattern around the inside diameter (ID) of the splines to completely fill the splines.
Install the transfer case.
NOTE: Refer to Fastener Notice .
Install the transfer case-to-transmission bolts.
Tighten: Tighten the case-to-transmission bolts to 60 N.m (44 lb ft).
Remove the adjustable jack from the transfer case.

Fig 2: Installing Propeller Shaft To Transfer Case Flange

Courtesy of GENERAL MOTORS CORP.

Install the transmission mount assembly. Refer to Transmission Rear Mount Replacement (RWD)Transmission Rear Mount Replacement (AWD) .
Remove the jack and block of wood from under the transmission.
Install the front propeller shaft. Refer to Front Propeller Shaft Replacement .
Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (RWD) or Rear Propeller Shaft Replacement (AWD) .
Install the exhaust system. Refer to Exhaust System Replacement .
Refill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .