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Home › GMC › 2005 › Jimmy Part Time, Standard › Repair and Diagnosis › Transmission › Transfer Case › Transfer Case - NVG 233-NP1 › Repair Instructions › Transfer Case Assembly Replacement › Installation Procedure

Installation Procedure

    Fig 1: View Of Transfer Case Gasket
    GM654219Courtesy of GENERAL MOTORS CORP.
  1. Install a new to the transfer case gasket (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 assembly.
    3. Fig 2: Identifying Transfer Case Upper Retaining Nuts
    GM648011Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the transfer case retaining nuts.

    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.

    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 (4WD, ZR2) or Transmission Support Replacement (RWD) 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 to 46 N.m (35 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. Install the motor/encoder electrical wiring harness.
    10. Fig 7: Locating Vacuum Line For Transfer Case Vacuum Switch
    GM767792Courtesy of GENERAL MOTORS CORP.
  10. Install the vacuum line to the transfer case vacuum switch.
    11. Fig 8: Locating Engine Brace Mounting Bolt
    GM648043Courtesy of GENERAL MOTORS CORP.
  11. Install the transfer case brace left side shown, if equipped.
  12. Install the transfer case brace bolt at the transfer case.

    Tighten:  Tighten the transfer case brace bolt to 60 N.m (44 lb ft).

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

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

  14. Install the rear propeller shaft.
  15. Install the front propeller shaft. 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. Refer to Transfer Case Shield Replacement .
  18. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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