GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Express - AWD 🢒 Preface 🢒 Cautions and Notices 🢒 Transfer Case Assembly Replacement

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement .
  3. Drain the transfer case. Refer to Transfer Case Fluid Replacement .
  4. Remove the rear propeller shaft from the transfer case. Refer to One-Piece Propeller Shaft Replacement .
  5. Remove the front propeller shaft from the transfer case. Refer to Front Propeller Shaft Replacement .

    6. Object Number: 860435 Size: SH
  6. Remove the vent hose from the transfer case.

    7. Object Number: 860433 Size: SH
  7. Disconnect the electrical connector from the speed sensor.
  8. Unclip the fuel lines from the fuel line bracket.
  9. Install a suitable transmission jack to the transfer case.
  10. Remove the nuts from the transfer case to the adapter.

    11. Object Number: 860429 Size: SH

    Important: Pull straight back on the transfer case in order to position the transfer case so that the transfer case can be turned parallel to the transmission.

  11. Remove the transfer case from the transfer case adapter.
  12. Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
  13. Lower the transfer case.
  14. Remove the gasket from the transfer case.
  15. Remove the transfer case from the transmission jack.

Installation Procedure

    Object Number: 860429 Size: SH
  1. Install the transfer case on a suitable transmission jack.

    2. Important: When installing a new transfer case gasket, ensure that the locator tab is facing up for proper installation. Install the gasket without the use of any type of sealant or of lubricant.

  2. Install a new transfer case adapter gasket.
  3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
  4. Raise the transfer case into position.
  5. Rotate the transfer case so that the transfer case is aligned with the adapter.
  6. Install the transfer case on the adapter.

    7. Notice: Refer to Fastener Notice in the Preface section.

  7. Install the mounting nuts for the transfer case.

    8. Tighten
    Tighten the mounting nuts to 50 N·m (37 lb ft).

  8. Install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement .
  9. Remove the transmission jack.

    10. Object Number: 860433 Size: SH
  10. Install the electrical connector to the speed sensor.

    11. Object Number: 860435 Size: SH
  11. Install the vent hose to the vent tube.
  12. Install the fuel lines to the fuel line bracket.
  13. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement .
  14. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement .
  15. Fill the transfer case with the proper transfer case fluid. Refer to Transfer Case Fluid Replacement .
  16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .