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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 115 (TRANSFER CASE - SERVICING)REMOVAL & INSTALLATIONADAPTERINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal.
  1. Install the new seal on the adapter. See Figure.
    NOTE: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.
  2. Install the adapter to the transmission.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  3. Install the adapter mounting bolts to the transmission.

    Tighten 

    Tighten the mounting bolts to 50 N.m (37 lb ft).

    NOTE: The locating tab on the gasket should always be pointing up
  4. Install the new gasket to the adapter.
  5. Install the transfer case to the adapter. Refer to TRANSFER CASE .
  6. Install the transmission support member. Refer to TRANSMISSION SUPPORT REPLACEMENT in FRAME AND UNDERBODY .
  7. Remove the transmission jack from the transmission.
  8. Check the fluid level of the transfer case. Refer to DRAINING & REFILLING .
  9. Lower the vehicle.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.