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Home >> Chevrolet >> 2003 >> Tracker 2D Utility, RWD, Automatic >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - Tracker >> Repair Instructions >> Transfer Case Replacement >> Installation Procedure

Installation Procedure

  1. Raise the transfer case into position and slide it onto the transmission output shaft.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the 10 transfer case-to-transmission bolts.

    Tighten 

    1. Tighten the 10 transfer case-to-transmission bolts to 28 N.m (21 lb ft).
  3. Install the breather hose to the gearshift lever case. Secure with the 1 clamp.
  4. Install the breather hose to the cover. Secure with the 1 clamp.
  5. Install the gearshift lever case to the rear case manual transmission equipped vehicles.
  6. Install the transfer case crossmember (1) to the undercarriage. Secure the crossmember with the 6 bolts (3).

    Tighten 

    1. Tighten the transfer case crossmember bolts to 50 N.m (37 lb ft).
  7. Install the following:
    • The skid plate (2)
    • The 2 transfer case braces
  8. Secure the skid plate and the 2 braces with the 6 nuts and the bolts (1,4).

    Tighten 

    1. Tighten the transfer case skid plate bolts and the nuts to 50 N.m (37 lb ft).
    Fig 1: Crossmember Bolts
    G01469793Courtesy of GENERAL MOTORS CORP.
  9. Remove the hydraulic jack from under the transfer case.
  10. Install the sensor harness to the crossmember.
  11. Install the ground wire and bolt.
  12. Install the rear propeller shaft into the vehicle aligning the reference marks made during the removal. Secure the rear propeller shaft with the 4 bolts and 4 nuts.

    Tighten 

    1. Tighten the rear propeller shaft bolts and nuts to 50 N.m (37 lb ft).
  13. Install the front propeller shaft into the vehicle aligning the reference marks made during removal. Secure the front propeller shaft the 4 bolts and the 4 nuts, if equipped.

    Tighten 

    1. Tighten the front propeller shaft bolts and nuts to 50 N.m (37 lb ft).
  14. Apply GM P/N 12346004 or the equivalent, to the threaded portion of the transfer case drain plug.
  15. Connect the VSS (2) to the case.
    Fig 2: Connecting VSS To Case
    G01469794Courtesy of GENERAL MOTORS CORP.
  16. Install the transfer case drain plug (2) into the transfer case.

    Tighten 

    1. Tighten the transfer case drain plug to 28 N.m (21 lb ft).
  17. Add approximately 1.7 liters (1.8 qts) of 75W-90 GL4 lubricant, or the equivalent, into the transfer case oil level/filler plug hole. The oil level should be even with the bottom of the oil level/filler plug (1).
  18. Apply GM P/N 12346004

    (Canadian P/N 10953480), or the equivalent, to the threaded portion of the transfer case oil level/filler plug (1).

  19. Install the transfer case oil level/filer plug (1) into the transfer case.

    Tighten 

    1. Tighten the transfer case oil level/filler plug (1) to 28 N.m (21 lb ft).
  20. Lower the vehicle.
  21. Install the 4 bolts to the fan shroud at the radiator.

    Tighten 

    1. Tighten the fan shroud bolt to 10 N.m (89 lb in).
    Fig 3: Filler & Drain Plug
    G01469795Courtesy of GENERAL MOTORS CORP.
  22. Connect the four-wheel drive switch electrical connector (2) to the four-wheel drive switch (1).
  23. Install the four-wheel drive low switch electrical connector (3) to the four-wheel drive low switch (4).
  24. Install the gearshift control lever. Refer to SHIFT LEVER REPLACEMENT - ON VEHICLE .
  25. Connect the negative battery cable.
    Fig 4: Locating Four-Wheel Drive Switch Electrical Connector
    G01469796Courtesy of GENERAL MOTORS CORP.
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