Tuesday, May 3, 2011

Have to remove transmission to replace clutch on 2001 GMC Sierra?


Transmission Removal & Installation


Nv3500



  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove or disconnect the following:

    Shift lever
    Shift tower
    Transmission oil
    If equipped with a transfer case, remove the front propeller shaft
    Rear propeller shaft.

  3. If equipped with a transfer case, remove or disconnect the following:

    Two transfer case shields
    Manual transfer case shift linkage

    Click image to see an enlarged view

    Fig. NV3500 removal-Sierra & Silverado

    Bolt securing the left side support brace to the transmission
    Bolt and stud securing the left side support brace to the transfer case
    Bolt securing the right side support brace to the transmission
    Bolt securing the right side support brace to the transfer case

  4. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.
  5. Disconnect the wiring harness and connectors from the vehicle speed sensor, backup lamp switch, and transmission harness retainers.
  6. If equipped with a 4.3L engine, remove the two bolts securing the clutch housing cover. Remove the transmission rear mount. Support the transmission with a transmission jack.
  7. Remove or disconnect the following:

    Bolts securing the bottom right side of the transmission to the engine
    Stud securing the right side of the transmission to the engine
    Bolt and six studs securing the transmission to the engine

  8. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.

    Transmission from the vehicle
    Clutch plate and the clutch cover from the engine flywheel, if required


To install:

  1. Install the clutch plate and the clutch cover to the engine flywheel if removed.
  2. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  3. Install or connect the following:

    Stud securing the right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
    Bolts securing the bottom right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
    Clutch housing cover using the two bolts (4.3L engine). Tighten the bolts to 10 ft. lbs. (14 Nm).
    Transmission rear mount
    Clutch line to the concentric slave cylinder

  4. If equipped with a transfer case, install or connect the following:

    Right side support brace-to-transmission bolt and tighten to 37 ft. lbs. (50 Nm)
    Right side support brace-to-transfer case bolts and tighten to 37 ft. lbs. (50 Nm)
    Left side support brace-to-transfer case bolt(s) and stud and tighten to 37 ft. lbs. (50 Nm)
    Left side support brace-to-transmission bolts and tighten to 37 ft. lbs. (50 Nm)
    Manual transfer case shift linkage.
    Two transfer case shields
    Front propeller shaft

  5. Install or connect the following:

    The rear propeller shaft.
    The shift tower.
    Transmission with transmission fluid
    Shift lever


  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove or disconnect the following:

    Shift lever
    Shift tower
    Transmission oil
    If equipped with a transfer case, remove the front propeller shaft
    Rear propeller shaft.

  3. If equipped with a transfer case, remove or disconnect the following:

    Two transfer case shields
    Manual transfer case shift linkage

    Click image to see an enlarged view

    Fig. NV3500 removal

    Bolt securing the left side support brace to the transmission
    Bolt and stud securing the left side support brace to the transfer case
    Bolt securing the right side support brace to the transmission
    Bolt securing the right side support brace to the transfer case

  4. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.
  5. Disconnect the wiring harness and connectors from the vehicle speed sensor, backup lamp switch, and transmission harness retainers.
  6. If equipped with a 4.3L engine, remove the two bolts securing the clutch housing cover. Remove the transmission rear mount. Support the transmission with a transmission jack.
  7. Remove or disconnect the following:

    Bolts securing the bottom right side of the transmission to the engine
    Stud securing the right side of the transmission to the engine
    Bolt and six studs securing the transmission to the engine

  8. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.

    Transmission from the vehicle
    Clutch plate and the clutch cover from the engine flywheel, if required


To install:

  1. Install the clutch plate and the clutch cover to the engine flywheel if removed.
  2. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  3. Install or connect the following:

    Stud securing the right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
    Bolts securing the bottom right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
    Clutch housing cover using the two bolts (4.3L engine). Tighten the bolts to 10 ft. lbs. (14 Nm).
    Transmission rear mount
    Clutch line to the concentric slave cylinder

  4. If equipped with a transfer case, install or connect the following:

    Right side support brace-to-transmission bolt and tighten to 37 ft. lbs. (50 Nm)
    Right side support brace-to-transfer case bolts and tighten to 37 ft. lbs. (50 Nm)
    Left side support brace-to-transfer case bolt(s) and stud and tighten to 37 ft. lbs. (50 Nm)
    Left side support brace-to-transmission bolts and tighten to 37 ft. lbs. (50 Nm)
    Manual transfer case shift linkage.
    Two transfer case shields
    Front propeller shaft

  5. Install or connect the following:

    The rear propeller shaft.
    The shift tower.
    Transmission with transmission fluid
    Shift lever


Nv4500



  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove or disconnect the following:

    The shift lever
    The shift tower
    The transmission oil
    Front propeller shaft, 4WD only
    Rear propeller shaft
    Two transfer case shields
    Manual transfer case shift linkage, if equipped
    Two bolts securing the right side support bracket to the transmission

  3. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.

    Click image to see an enlarged view

    Fig. NV4500 removal-Sierra and Silverado



    Vehicle Speed Sensor (VSS) connector and harness
    Backup lamp switch connector and harness
    Transmission harness retainers
    Clutch housing cover-to-transmission bolts (4)
    Left and right side transmission-to-engine cover bolts
    Transmission rear mount. Support the transmission with a transmission jack.
    Bolts and studs securing the transmission to the engine.

  4. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover. Remove the transmission from the vehicle.
  5. Remove the clutch plate and the clutch cover from the engine flywheel if required.

To install:

  1. Install or connect the following:

    Clutch plate and the clutch cover to the engine flywheel, if removed

  2. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  3. Install or connect the following:

    Right and left side transmission to engine cover bolts and tighten to 10 ft. lbs. (14 Nm)
    Clutch cover-to-transmission bolts and tighten to 10 ft. lbs. (14 Nm)
    Transmission rear mount
    Clutch line to the slave cylinder
    Right side support bracket-to-transmission bolts (2). Tighten to 37 ft. lbs. (50 Nm).
    Manual transfer case shift linkage, if removed
    Two transfer case shields, if equipped
    Front propeller shaft, if equipped
    Rear propeller shaft
    Shift tower
    Transmission with transmission fluid
    Shift lever


  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove or disconnect the following:

    The shift lever
    The shift tower
    The transmission oil
    Front propeller shaft, 4WD only
    Rear propeller shaft
    Two transfer case shields
    Manual transfer case shift linkage, if equipped
    Two bolts securing the right side support bracket to the transmission

  3. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.

    Click image to see an enlarged view

    Fig. NV4500 removal



    Vehicle Speed Sensor (VSS) connector and harness
    Backup lamp switch connector and harness
    Transmission harness retainers
    Clutch housing cover-to-transmission bolts (4)
    Left and right side transmission-to-engine cover bolts
    Transmission rear mount. Support the transmission with a transmission jack.
    Bolts and studs securing the transmission to the engine.

  4. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover. Remove the transmission from the vehicle.
  5. Remove the clutch plate and the clutch cover from the engine flywheel if required.

To install:

  1. Install or connect the following:

    Clutch plate and the clutch cover to the engine flywheel, if removed

  2. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  3. Install or connect the following:

    Right and left side transmission to engine cover bolts and tighten to 10 ft. lbs. (14 Nm)
    Clutch cover-to-transmission bolts and tighten to 10 ft. lbs. (14 Nm)
    Transmission rear mount
    Clutch line to the slave cylinder
    Right side support bracket-to-transmission bolts (2). Tighten to 37 ft. lbs. (50 Nm).
    Manual transfer case shift linkage, if removed
    Two transfer case shields, if equipped
    Front propeller shaft, if equipped
    Rear propeller shaft
    Shift tower
    Transmission with transmission fluid
    Shift lever


Zf S6-650 Transmissions



  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove the shift lever.
  3. Raise and suitably support the vehicle.
  4. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft.
  5. If equipped with 4 wheel drive (4WD), remove the transfer case.
  6. Disconnect the clutch slave cylinder hydraulic hose quick connect at the master cylinder.
  7. Disconnect the clutch slave cylinder line retaining clips.
  8. If equipped with a 6.6L engine, disconnect the power take off, backup lamp and vehicle speed sensor connectors.
  9. Remove the engine harness clips from the fuel feed/return brackets.
  10. Remove the PTO connector from the fuel feed/return bracket.
  11. Reposition the harness.
  12. Remove the fuel lines from the fuel feed/return brackets.
  13. If equipped with a 8.1L engine, disconnect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  14. Remove the engine harness clips from the fuel feed/return brackets.
  15. Remove the PTO connector from the fuel feed/return bracket.
  16. Remove the oxygen sensors connectors from the fuel feed/return hose clip and transmission bracket.
  17. Reposition the harness.
  18. Remove the fuel lines from the fuel feed/return brackets.
  19. If equipped with 4WD, remove the vent hose clip from the bracket.
  20. Remove the vent hose clip nut and clip.
  21. If equipped with 4WD, remove the vent hose clip from the fuel feed/return bracket.
  22. Remove the starter.
  23. Remove the exhaust pipe hanger bracket bolts and bracket.
  24. Support the transmission with a suitable transmission jack.
  25. Remove the transmission support
  26. Remove the transmission bolts/studs.
  27. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  28. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  29. Remove the insulator from the top of the transmission.

To install:

  1. Install the insulator to the top of the transmission.
    NOTE
    Connect the clutch slave cylinder hose quick connect to the master cylinder before the transmission is fully installed. Failure to connect the hose could cause damage to the clutch pressure plate.

  2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  3. Rotate the transmission clockwise onto the clutch hub splines.
  4. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  5. Install the transmission studs and tighten to 37 ft. lbs. (50 Nm).
  6. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  7. Install the transmission support.
  8. Remove the transmission jack.
  9. Install the exhaust pipe hanger bracket and bolts.
  10. Install the starter.
  11. If equipped with 4WD, install the vent hose clip to the fuel feed/return bracket.
  12. Install the vent hose clip and nut.
  13. Install the vent hose clip to the bracket.
  14. Install the fuel lines to the fuel feed/return brackets.
  15. Position the harness.
  16. Install the oxygen sensors connectors to the fuel feed/return hose clip and transmission bracket.
  17. Install the PTO connector to the fuel feed/return bracket.
  18. Install the engine harness clips to the fuel feed/return brackets.
  19. If equipped with a 8.1L engine, connect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  20. Connect the clutch slave cylinder line retaining clips.
  21. If equipped with 4WD, install the transfer case.
  22. If equipped with a 6.6L engine, connect the power take off, backup lamp and vehicle speed sensor connectors.
  23. If vehicle is a 2WD, install the rear propeller shaft.
  24. Lower the vehicle.
  25. Install the shift lever.
  26. Fill the transmission with fluid.
  27. Bleed the clutch hydraulic system, if necessary.
  28. Connect the battery cables.

  1. Shift the transmission into 3rd or 4th speed gear.
  2. Remove the shift lever.
  3. Raise and suitably support the vehicle.
  4. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft.
  5. If equipped with 4 wheel drive (4WD), remove the transfer case.
  6. Disconnect the clutch slave cylinder hydraulic hose quick connect at the master cylinder.
  7. Disconnect the clutch slave cylinder line retaining clips.
  8. If equipped with a 6.6L engine, disconnect the power take off, backup lamp and vehicle speed sensor connectors.
  9. Remove the engine harness clips from the fuel feed/return brackets.
  10. Remove the PTO connector from the fuel feed/return bracket.
  11. Reposition the harness.
  12. Remove the fuel lines from the fuel feed/return brackets.
  13. If equipped with a 8.1L engine, disconnect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  14. Remove the engine harness clips from the fuel feed/return brackets.
  15. Remove the PTO connector from the fuel feed/return bracket.
  16. Remove the oxygen sensors connectors from the fuel feed/return hose clip and transmission bracket.
  17. Reposition the harness.
  18. Remove the fuel lines from the fuel feed/return brackets.
  19. If equipped with 4WD, remove the vent hose clip from the bracket.
  20. Remove the vent hose clip nut and clip.
  21. If equipped with 4WD, remove the vent hose clip from the fuel feed/return bracket.
  22. Remove the starter.
  23. Remove the exhaust pipe hanger bracket bolts and bracket.
  24. Support the transmission with a suitable transmission jack.
  25. Remove the transmission support
  26. Remove the transmission bolts/studs.
  27. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  28. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  29. Remove the insulator from the top of the transmission.

To install:

  1. Install the insulator to the top of the transmission.
    NOTE
    Connect the clutch slave cylinder hose quick connect to the master cylinder before the transmission is fully installed. Failure to connect the hose could cause damage to the clutch pressure plate.

  2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  3. Rotate the transmission clockwise onto the clutch hub splines.
  4. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  5. Install the transmission studs and tighten to 37 ft. lbs. (50 Nm).
  6. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  7. Install the transmission support.
  8. Remove the transmission jack.
  9. Install the exhaust pipe hanger bracket and bolts.
  10. Install the starter.
  11. If equipped with 4WD, install the vent hose clip to the fuel feed/return bracket.
  12. Install the vent hose clip and nut.
  13. Install the vent hose clip to the bracket.
  14. Install the fuel lines to the fuel feed/return brackets.
  15. Position the harness.
  16. Install the oxygen sensors connectors to the fuel feed/return hose clip and transmission bracket.
  17. Install the PTO connector to the fuel feed/return bracket.
  18. Install the engine harness clips to the fuel feed/return brackets.
  19. If equipped with a 8.1L engine, connect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  20. Connect the clutch slave cylinder line retaining clips.
  21. If equipped with 4WD, install the transfer case.
  22. If equipped with a 6.6L engine, connect the power take off, backup lamp and vehicle speed sensor connectors.
  23. If vehicle is a 2WD, install the rear propeller shaft.
  24. Lower the vehicle.
  25. Install the shift lever.
  26. Fill the transmission with fluid.
  27. Bleed the clutch hydraulic system, if necessary.
  28. Connect the battery cables.





Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the lubricant from the axle housing
  3. Remove or disconnect the following:

    Driveshaft
    Wheel, the brake drum or hub and the drum assembly
    Parking brake cable from the lever and at the brake flange plate
    Hydraulic brake lines from the connectors
    Shock absorbers from the axle brackets
    Vent hose from the axle vent fitting, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Stabilizer shaft, if equipped

  4. Support the axle assembly with a jack.

    U-bolts
    Spring plates and spacers
    Axle assembly


To install:

  1. Raise the axle assembly into position.
  2. Install or connect the following:

    U-bolts
    Spring plates and spacers
    Nuts and washers on the U-bolts. Torque the nuts to 81 ft. lbs. (110 Nm).
    Stabilizer shaft, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Vent hose at the axle vent fitting, if equipped
    Shock absorbers at the axle brackets
    Hydraulic brake lines
    Parking brake cable
    Wheels
    Driveshaft

  3. Fill the axle housing.

  1. Remove or disconnect the following:

    Axle lubricant
    Propeller shaft
    Wheel assemblies
    Parking brake cable
    Brake calipers
    Shock absorbers from the axle brackets
    Vent hose from the rear axle vent fitting
    Nuts and the washers from the U-bolts
    U-bolts, the spring plates and the spacers from the axle assembly

  2. Lower the axle assembly.

To install:

  1. Place the rear axle assembly under the vehicle. Align the rear axle assembly with the springs. Connect the spacers, the spring plates and the U-bolts to the rear axle. Raise the rear axle assembly into position.
  2. Install or connect the following:

    Washers and nuts to the U-bolts. Tighten the nuts to 59 ft. lbs. (80 Nm) first, then to 89 ft. lbs. (120 Nm).
    Vent hose to the rear axle vent fitting
    Shock absorbers to the rear axle
    Brake calipers
    Parking brake cable
    Wheel assemblies
    Propeller shaft

  3. Fill the rear axle.
  4. Bleed the brake system.
  5. Remove the supports and lower the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the lubricant from the axle housing
  3. Remove or disconnect the following:

    Driveshaft
    Wheel, the brake drum or hub and the drum assembly
    Parking brake cable from the lever and at the brake flange plate
    Hydraulic brake lines from the connectors
    Shock absorbers from the axle brackets
    Vent hose from the axle vent fitting, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Stabilizer shaft, if equipped

  4. Support the axle assembly with a jack.

    U-bolts
    Spring plates and spacers
    Axle assembly


To install:

  1. Raise the axle assembly into position.
  2. Install or connect the following:

    U-bolts
    Spring plates and spacers
    Nuts and washers on the U-bolts. Torque the nuts to 81 ft. lbs. (110 Nm).
    Stabilizer shaft, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Vent hose at the axle vent fitting, if equipped
    Shock absorbers at the axle brackets
    Hydraulic brake lines
    Parking brake cable
    Wheels
    Driveshaft

  3. Fill the axle housing.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the lubricant from the axle housing
  3. Remove or disconnect the following:

    Driveshaft
    Wheel, the brake drum or hub and the drum assembly
    Parking brake cable from the lever and at the brake flange plate
    Hydraulic brake lines from the connectors
    Shock absorbers from the axle brackets
    Vent hose from the axle vent fitting, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Stabilizer shaft, if equipped

  4. Support the axle assembly with a jack.

    U-bolts
    Spring plates and spacers
    Axle assembly


To install:

  1. Raise the axle assembly into position.
  2. Install or connect the following:

    U-bolts
    Spring plates and spacers
    Nuts and washers on the U-bolts. Torque the nuts to 81 ft. lbs. (110 Nm).
    Stabilizer shaft, if equipped
    Height sensing and brake proportional valve linkage, if equipped
    Vent hose at the axle vent fitting, if equipped
    Shock absorbers at the axle brackets
    Hydraulic brake lines
    Parking brake cable
    Wheels
    Driveshaft

  3. Fill the axle housing.
-----------

Removal & Installation



  1. Remove the transfer case shield.
  2. Remove the front propeller shaft.
  3. Disconnect the transfer case switch electrical connector.
  4. Disconnect the encoder motor electrical connector.
  5. Remove the encoder motor bolts.
  6. Remove the encoder motor.
  7. Remove the actuator insulator gasket.
  8. If replacing the encoder motor, remove the locating pins from the old motor.

To install:


NOTE
If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts.

  1. Install the locating pins to the new encoder motor.
  2. Position a new actuator insulator gasket to the transfer case.
  3. Install the encoder motor.
  4. Install encoder motor bolts and tighten in sequence to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. Encoder motor tightening sequence

  5. Connect the encoder motor electrical connector.
  6. Connect the transfer case switch electrical connector.
  7. Install the front propeller shaft.
  8. Install the transfer case shield.

  1. Remove the transfer case shield.
  2. Remove the front driveshaft.
  3. Disconnect the transfer case switch electrical connector.
  4. Disconnect the encoder motor electrical connector.
  5. Remove the encoder motor bolts.
  6. Remove the encoder motor.
  7. Remove the actuator insulator gasket.
  8. If replacing the encoder motor, remove the locating pins from the old motor.

To install:


NOTE
If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts.

  1. Install the locating pins to the new encoder motor.
  2. Position a new actuator insulator gasket to the transfer case.
  3. Install the encoder motor.
  4. Install encoder motor bolts and tighten in sequence to 15 ft. lbs. (20 Nm).
  5. Connect the encoder motor electrical connector.
  6. Connect the transfer case switch electrical connector.
  7. Install the front driveshaft.
  8. Install the transfer case shield.

    Click image to see an enlarged view

    Fig. Encoder motor tightening sequence


  1. Remove the transfer case shield.
  2. Remove the front propeller shaft.
  3. Disconnect the transfer case switch electrical connector.
  4. Disconnect the encoder motor electrical connector.
  5. Remove the encoder motor bolts.
  6. Remove the encoder motor.
  7. Remove the actuator insulator gasket.
  8. If replacing the encoder motor, remove the locating pins from the old motor.

To install:


NOTE
If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts.

  1. Install the locating pins to the new encoder motor.
  2. Position a new actuator insulator gasket to the transfer case.
  3. Install the encoder motor.
  4. Install encoder motor bolts and tighten in sequence to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. Encoder motor tightening sequence

  5. Connect the encoder motor electrical connector.
  6. Connect the transfer case switch electrical connector.
  7. Install the front propeller shaft.
  8. Install the transfer case shield.

  1. Remove the transfer case shield.
  2. Remove the front propeller shaft.
  3. Disconnect the transfer case switch electrical connector.
  4. Disconnect the encoder motor electrical connector.
  5. Remove the encoder motor bolts.
  6. Remove the encoder motor.
  7. Remove the actuator insulator gasket.
  8. If replacing the encoder motor, remove the locating pins from the old motor.

To install:


NOTE
If the encoder motor is being replaced because it is defective, ensure that the transfer case is in the neutral position. Manually shift the transfer case at the shift shaft, using a crescent wrench if necessary. When installing the encoder motor, ensure that the encoder motor is indexed correctly and the motor is flat against the transfer case before tightening the bolts.

  1. Install the locating pins to the new encoder motor.
  2. Position a new actuator insulator gasket to the transfer case.
  3. Install the encoder motor.
  4. Install encoder motor bolts and tighten in sequence to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. Encoder motor tightening sequence

  5. Connect the encoder motor electrical connector.
  6. Connect the transfer case switch electrical connector.
  7. Install the front propeller shaft.
  8. Install the transfer case shield.
------------------

Transfer Case Removal & Installation


  1. Remove or disconnect the following:

    Transfer case shields
    Front propeller shaft
    Rear propeller shaft
    Shift rod from the transfer case
    Vent hose from the transfer case
    Vehicle Speed Sensor (VSS) electrical connectors
    All necessary wiring harnesses from the transfer case

  2. Support the transfer case with a transmission jack.
  3. If equipped with a NV3500 manual transmission, remove or disconnect the following:

    Bolt securing the left side support brace to the transmission
    Bolt and stud securing the left side support brace to the transfer case
    Two bolts securing the right side support brace to the transmission and transfer case

  4. Remove or disconnect the following:

    Six nuts securing the transfer case and bracket to the transmission or transmission adapter, as applicable
    Transfer case
    Gasket, then discard


To install:

  1. Install a new gasket to the transmission. Use Teflon pipe sealant GM P/N 12346004 in order to hold the gasket in place.
  2. Raise and position the transfer case to the vehicle.
  3. Install or connect the following:

    Six nuts securing the transfer case and bracket to the transmission adapter or transmission. Tighten to 37 ft. lbs. (50 Nm).

  4. If equipped with a manual transmission, install or connect the following:

    Bolt securing the left side support brace to the transmission and tighten to 37 ft. lbs. (50 Nm)
    Bolt and stud securing the left side support brace to the transfer case and tighten to 37 ft. lbs. (50 Nm)
    Two bolts securing the right side support brace to the transmission and transfer case and tighten to 37 ft. lbs. (50 Nm)

  5. Install or connect the following:

    Vent hose to the transfer case

  6. Check the transfer case oil level.

    VSS electrical connectors
    Wiring harness to the transfer case
    Shift rod to the transfer case
    Front and rear propeller shafts
    Transfer case shields

  7. Lower the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain transfer case of lubricant.
  3. Remove or disconnect the following:

    Negative battery cable
    Skid plate, if equipped
    Vent hose clamp at the transfer case
    Front driveshaft at the transfer case and support it aside
    Rear driveshaft and support it aside
    Electrical connections at the transfer case
    Transfer case shift linkage

  4. Support the transfer case with a transmission jack.

    Transmission to transfer case bolts and spring washers
    Transfer case assembly and gasket

  5. Carefully lower the transfer case.

To install:

  1. Carefully raise the transfer case into position.
  2. Install or connect the following:

    New gasket to the transmission using gasket sealer to hold it in place
    Transfer case onto the transmission or transmission adapter. Torque the bolts to 33 ft. lbs. (45 Nm).
    Electrical harness connectors to the transfer case connections
    Transfer case shift linkage and make the proper adjustments
    Front and rear driveshafts

  3. Refill the transfer case with DEXRON®IIE automatic transmission fluid.

    Skid plate, if equipped
    Negative battery cable

  4. Test drive for proper operation.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain transfer case of lubricant.
  3. Remove or disconnect the following:

    Negative battery cable
    Skid plate, if equipped
    Vent hose clamp at the transfer case
    Front driveshaft at the transfer case and support it aside
    Rear driveshaft and support it aside
    Electrical connections at the transfer case
    Transfer case shift linkage

  4. Support the transfer case with a transmission jack.

    Transmission to transfer case bolts and spring washers
    Transfer case assembly and gasket

  5. Carefully lower the transfer case.

To install:

  1. Carefully raise the transfer case into position.
  2. Install or connect the following:

    New gasket to the transmission using gasket sealer to hold it in place
    Transfer case onto the transmission or transmission adapter. Torque the bolts to 33 ft. lbs. (45 Nm).
    Electrical harness connectors to the transfer case connections
    Transfer case shift linkage and make the proper adjustments
    Front and rear driveshafts

  3. Refill the transfer case with DEXRON®IIE automatic transmission fluid.

    Skid plate, if equipped
    Negative battery cable

  4. Test drive for proper operation.

  1. Remove or disconnect the following:

    Transfer case shields
    Front propeller shaft
    Rear propeller shaft
    Shift rod from the transfer case
    Vent hose from the transfer case
    Vehicle Speed Sensor (VSS) electrical connectors
    All necessary wiring harnesses from the transfer case

  2. Support the transfer case with a transmission jack.
  3. Remove or disconnect the following:

    Six nuts securing the transfer case and bracket to the transmission or transmission adapter, as applicable
    Transfer case
    Gasket, then discard

    Click image to see an enlarged view

    Fig. Transfer case mounting-Express/Savana shown; Avalanche similar



To install:

  1. Install a new gasket to the transmission. Use Teflon pipe sealant GM P/N 12346004 in order to hold the gasket in place.
  2. Raise and position the transfer case to the vehicle.
  3. Install or connect the following:

    Six nuts securing the transfer case and bracket to the transmission adapter or transmission. Tighten to 37 ft. lbs. (50 Nm).

  4. If equipped with a manual transmission, install or connect the following:

    Bolt securing the left side support brace to the transmission and tighten to 37 ft. lbs. (50 Nm)
    Bolt and stud securing the left side support brace to the transfer case and tighten to 37 ft. lbs. (50 Nm)
    Two bolts securing the right side support brace to the transmission and transfer case and tighten to 37 ft. lbs. (50 Nm)

  5. Install or connect the following:

    Vent hose to the transfer case

  6. Check the transfer case oil level.

    VSS electrical connectors
    Wiring harness to the transfer case
    Shift rod to the transfer case
    Front and rear propeller shafts
    Transfer case shields

  7. Lower the vehicle.

  1. Remove or disconnect the following:

    Transfer case shields
    Front propeller shaft
    Rear propeller shaft
    Shift rod from the transfer case
    Vent hose from the transfer case
    Vehicle Speed Sensor (VSS) electrical connectors
    All necessary wiring harnesses from the transfer case

  2. Support the transfer case with a transmission jack.
  3. If equipped with a NV3500 manual transmission, remove or disconnect the following:

    Bolt securing the left side support brace to the transmission
    Bolt and stud securing the left side support brace to the transfer case
    Two bolts securing the right side support brace to the transmission and transfer case

  4. Remove or disconnect the following:

    Six nuts securing the transfer case and bracket to the transmission or transmission adapter, as applicable
    Transfer case
    Gasket, then discard

    Click image to see an enlarged view

    Fig. Transfer case mounting nuts (1), transfer case (2) and transfer case gasket (3)



To install:

  1. Install a new gasket to the transmission. Use Teflon pipe sealant GM P/N 12346004 in order to hold the gasket in place.
  2. Raise and position the transfer case to the vehicle.
  3. Install or connect the following:

    Six nuts securing the transfer case and bracket to the transmission adapter or transmission. Tighten to 37 ft. lbs. (50 Nm).

  4. If equipped with a manual transmission, install or connect the following:

    Bolt securing the left side support brace to the transmission and tighten to 37 ft. lbs. (50 Nm)
    Bolt and stud securing the left side support brace to the transfer case and tighten to 37 ft. lbs. (50 Nm)
    Two bolts securing the right side support brace to the transmission and transfer case and tighten to 37 ft. lbs. (50 Nm)

  5. Install or connect the following:

    Vent hose to the transfer case

  6. Check the transfer case oil level.

    VSS electrical connectors
    Wiring harness to the transfer case
    Shift rod to the transfer case
    Front and rear propeller shafts
    Transfer case shields

  7. Lower the vehicle.


max