GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 36660-A Torque Angle Meter
    • J 44467 Slide Hammer
    • J 6125-1B Slide Hammer Adapter
    • J 44755 Holding Fixture

Removal Procedure

Important: Transmission oil circulates between the transmission and the transfer case. In situations where transmission failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. Refer to Transfer Case Transmission Fiber Material Cleaning in Unit Repair.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.

  3. Object Number: 630583  Size: SH
  4. Remove the drain plug (1) drain the transfer case oil.

  5. Object Number: 630590  Size: SH
  6. Remove the drain plug (1) in order to drain the transmission fluid.
  7. Disconnect the vehicle speed sensor electrical connector.
  8. Remove the transfer case brace. Refer to Support Brace Replacement .

  9. Object Number: 630581  Size: SH
  10. Remove the vent tube clamp (1).
  11. Separate the vent tube from the vent tube bracket.
  12. Remove the vent tube from the transfer case.
  13. Notice: Removal and installation of the transfer case while the transmission is in vehicle may cause improper positioning of the park gear thrust bearing. If the transfer case fasteners are tightened while the park gear thrust bearing is out of position, the park gear thrust bearing, transmission, and/or the transfer case will be damaged.

  14. Remove the transfer case with the transaxle. Refer to Transmission Replacement in Automatic Transaxle - 4T65-E.
  15. Install the transaxle to the transmission support fixture. Refer to Transmission Support Fixture Assemble for the 4T65-E transaxle in Unit Repair.

  16. Object Number: 692584  Size: SH
  17. Remove and discard the left output shaft retaining ring (1).

  18. Object Number: 692583  Size: SH
  19. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
  20. Remove the transfer case side brace bolts (1-5), and the transfer case side brace (6).

  21. Object Number: 677381  Size: SH
  22. Remove the transfer case bolts (1-5).

  23. Object Number: 692590  Size: SH

    Caution: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

    Notice: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.

  24. Remove the transfer case (1) with the output shaft (2) from the transaxle (3).

  25. Object Number: 750020  Size: SH
  26. Install the transfer case assembly (1) to the J 44755 .
  27. Notice: Refer to Fastener Notice in the Preface section.

  28. Install the retaining bolts (2).
  29. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 750028  Size: SH
  30. Attach the J 6125-1B to the J 44467 .
  31. Install the J 44467 into the snap ring groove on the output shaft (510) and tighten securely.
  32. Use the J 6125-1B and the J 44467 to remove the output shaft.
  33. Remove the output shaft from the transfer case. Perform the following steps.

  34. Object Number: 692591  Size: SH
  35. Remove the transfer case seal (1) from the transfer case (2).

  36. Object Number: 630839  Size: SH
  37. Remove the oil dam (901) from the transaxle.

  38. Object Number: 630829  Size: SH
  39. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).

Installation Procedure

Important: If you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed. Refer to Transmission to Transfer Case End Play Check for the 4T65-E transaxle in Unit Repair.


    Object Number: 630829  Size: SH
  1. If you are replacing the transfer case, install the transfer case lower brace  (906) and the lower brace bolts (903). Do not tighten the bolts.

  2. Object Number: 692591  Size: SH
  3. Install a new seal transfer case seal (1).

  4. Object Number: 630839  Size: SH

    Important: The oil dam (901) must be installed with the notch aligned to the oil passage in the transaxle case (1).

  5. Install the oil dam (901) to the transaxle.

  6. Object Number: 621064  Size: SH
  7. Rotate the transaxle 90 degrees.
  8. Caution: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

  9. Install the transfer case to the transaxle.
  10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 677381  Size: SH
  11. Install the transfer case bolts (1) and (2).
  12. Tighten

    1. Tighten the bolts to 35 N·m (26 lb ft).
    2. Use the J 36660-A to rotate the bolts 160 degrees.
  13. Install the transfer case bolt (3).
  14. Tighten

    1. Tighten the bolt to 35 N·m (26 lb ft).
    2. Use the J 36660-A to rotate the bolts 70 degrees.
  15. Install the transfer case bolts (4) and (5).
  16. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 677386  Size: SH
  17. Install the transfer case side brace (905).
  18. Install and tighten the transfer case side brace bolts in the order shown.
  19. Tighten
    Tighten transfer case side brace bolts to 32 N·m (24 lb ft).


    Object Number: 692586  Size: SH
  20. Install the transfer case lower brace to transaxle bolt (1).
  21. Tighten
    Tighten the bolt to 56 N·m (42 lb ft).


    Object Number: 659370  Size: SH
  22. Tighten the transfer case lower brace to transfer case bolts (903).
  23. Tighten
    Tighten the bolts to 32 N·m (24 lb ft).

  24. Install the output shaft to the transmission. Refer to Output Shaft Assemble for the 4T65-E transaxle in Unit Repair.

  25. Object Number: 692584  Size: SH
  26. Install a new output shaft retaining ring  (1).
  27. Install the transaxle with the transfer case. Refer to Transmission Replacement in Automatic Transaxle - 4T65-E.

  28. Object Number: 630581  Size: SH
  29. Install the vent hose (2) and the clamp (1) to the transfer case.
  30. Install the vehicle speed sensor electrical connector.
  31. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  32. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to Transfer Case Fluid Replacement .

  33. Object Number: 630590  Size: SH
  34. Install the drain plug (1) and gasket to the case.
  35. Tighten
    Tighten the drain plug to 32 N·m (24 lb ft).

  36. Install the transfer case lower brace. Refer to Support Brace Replacement .
  37. Lower the vehicle.
  38. Inspect and adjust the transmission fluid level. Refer to Transmission Fluid Check in Automatic Transaxle - 4T65-E.