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Home >> GMC >> 2004 >> Jimmy 2D Utility, Automatic, Automatic >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - NVG 236-NP8 >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Transfer Case Gasket
    GM654219Courtesy of GENERAL MOTORS CORP.
  1. Install the new gasket to the transfer case adapter with the tab facing upward.
    2. IMPORTANT: The following service procedure should be performed with the aid of another technician.
  2. Install the transfer case to the transfer case adapter.
    3. Fig 2: View Of Transfer Case To Transfer Case Adapter Retaining Nuts
    GM648011Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the transfer case retaining nuts on the transfer case mounting studs.

    Tighten:  Tighten the transfer case retaining nuts to 55 N.m (40 lb ft).

    4. Fig 3: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  4. Install the transmission mount to the transfer case adapter.

    Tighten:  Tighten the transmission mount bolts to 47 N.m (35 lb ft).

    5. Fig 4: View Of Transmission Support Assembly
    GM680767Courtesy of GENERAL MOTORS CORP.
  5. Install the transmission support assembly. Refer to Transmission Support Replacement (RWD) or Transmission Support Replacement (4WD, ZR2) in Frame and Underbody.
    6. Fig 5: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  6. Install the transmission mount retaining nuts.

    Tighten:  Tighten the transmission mount retaining nuts and bolts to 40 N.m (30 lb ft).

  7. Remove the transmission jack from the transmission.
    8. Fig 6: View Of Motor/Encoder Electrical Connector
    GM662851Courtesy of GENERAL MOTORS CORP.
  8. Install the motor/encoder electrical connector.
    9. Fig 7: View Of Electrical Wiring Harness For Transfer Case
    GM647994Courtesy of GENERAL MOTORS CORP.
  9. Install the electrical wiring harness to the transfer case.
    10. Fig 8: Locating Vent Hose At Transfer Case
    GM715667Courtesy of GENERAL MOTORS CORP.
  10. Install the vent hose to the transfer case.
    11. Fig 9: View Of Brace For Transfer Case
    GM648043Courtesy of GENERAL MOTORS CORP.
  11. Install the transfer case brace left side shown, if equipped.
  12. Install the transfer case brace bolts at the transfer case.

    Tighten:  Tighten the transfer case to engine bolts to 60 N.m (44 lb ft).

  13. Install the transfer case brace bolt at the engine.

    Tighten:  Tighten the transfer case brace bolt to 47 N.m (35 lb ft).

  14. Install the rear propeller shaft in the vehicle.
  15. Install the front propeller shaft in the vehicle. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  16. Fill the transfer case with the approved fluid. Refer to Transfer Case Fluid Replacement .
  17. Install the transfer case shield to the vehicle. Refer to Transfer Case Shield Replacement .
  18. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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