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Home › Chevrolet › 2004 › Tracker RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 1 (Transfer Case) › Repair Instructions › Transfer Case Replacement › Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative (-) battery cable.
  2. Remove the 2 screws, the 2 plastic retainers and the rear console box from the floor.
  3. Remove the 2 screws, the 2 plastic retainers and the front console box from the floor.
  4. Remove the 1 screw and the transfer case gearshift control lever knob (1) from the transfer case gearshift control lever.
    5. Fig 1: View Of Gearshift Control Lever Knob
    GM167065Courtesy of GENERAL MOTORS CORP.
  5. Remove the 6 screws, the boot cover and the gearshift control lever boot (1) from the gearshift control lever (2).
  6. Remove the 1 clamp and the gearshift lever case boot from the gearshift lever case.
    7. Fig 2: View Of Gearshift Control Lever Boot & Control Lever
    GM167066Courtesy of GENERAL MOTORS CORP.
  7. Remove the gearshift control lever (1) from the gearshift lever case (2) by pushing down on the gearshift control lever pivot (3) and turning counterclockwise 90 degrees, 1/4 turn, and lifting up.
    8. Fig 3: View Of Gearshift Control Lever, Lever Case & Pivot
    GM167096Courtesy of GENERAL MOTORS CORP.
  8. Remove the four-wheel drive switch electrical connector (1) from the four wheel drive switch (2), if equipped.
    9. Fig 4: View Of 4WD Switch Electrical Connector & Drive Switch
    GM167506Courtesy of GENERAL MOTORS CORP.
  9. Remove the four-wheel drive low switch electrical connector (3) from the four-wheel drive low switch (4), if equipped.
  10. Remove the 4 bolts from the fan shroud at the radiator.
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Place a drain pan or suitable container under the transfer case.
    13. Fig 5: View Of 4WD Low Switch Electrical Connector & Drive Low Switch
    GM167508Courtesy of GENERAL MOTORS CORP.
  13. Remove the transfer case oil level/filler plug (1) from the transfer case.
  14. Remove the transfer case drain plug (2) from the transfer case and drain the transfer case oil.
    15. IMPORTANT: An index mark should be made on the front and rear propeller shaft pinion flange yokes and the front and rear differential pinion flanges to ensure that the front and rear propeller shafts are installed in the same positions from which they were removed. If this precaution is not observed, a driveline imbalance may result causing vibration, premature component wear or other undesirable conditions.
  15. Place an index mark on the front propeller shaft pinion flange yoke and the front deferential pinion flange, if equipped.
  16. Remove the 4 bolts, the 4 nuts and the front propeller shaft from the vehicle, if equipped.
  17. Place an index mark on the rear propeller shaft pinion flange yoke and the differential pinion flange.
  18. Remove the 4 bolts, the 4 nuts and the rear propeller shaft from the vehicle.
    19. Fig 6: View Of Drain Plug & Oil Level/Filler Plug
    GM627867Courtesy of GENERAL MOTORS CORP.
  19. Remove the VSS (2) from the case.
  20. Remove the sensor harness from the crossmember.
  21. Support the transfer case with a suitable hydraulic jack.
    22. Fig 7: Locating Speed Sensor & Connector
    GM480289Courtesy of GENERAL MOTORS CORP.
  22. Remove the following components:
    • The 6 nuts (1,4)
    • The 6 bolts
    • The transfer case skid plate (2)
    • The 2 transfer case braces
  23. Remove the 10 bolts and the transfer case crossmember (1) from the undercarriage.
  24. Remove the 1 clamp and the breather hose from the gearshift lever case.
  25. Remove the 1 clamp and the breather hose from the cover.
  26. Remove the 12 transfer case-to-transmission bolts.
  27. Slide the transfer case off the transmission output shaft and slowly lower the transfer case making sure there are no obstructions.
    28. Fig 8: View Of Undercarriage
    GM480323Courtesy of GENERAL MOTORS CORP.
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