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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 17 (TRANSFER CASE - BW 4473-NP3)REPAIR INSTRUCTIONS - ON VEHICLETRANSFER CASE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Transfer Case & Transfer Case Adapter
    GM860429Courtesy of GENERAL MOTORS CORP.
  1. Install the transfer case on a suitable transmission jack.
    2. IMPORTANT: When installing a new transfer case gasket, ensure that the locator tab is facing up for proper installation. Install the gasket without the use of any type of sealant or of lubricant.
  2. Install a new transfer case adapter gasket.
  3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
  4. Raise the transfer case into position.
  5. Rotate the transfer case so that the transfer case is aligned with the adapter.
  6. Install the transfer case on the adapter.
    7. NOTE: Refer to Fastener Notice .
  7. Install the mounting nuts for the transfer case.

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

  8. Install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement .
  9. Remove the transmission jack.
    10. Fig 2: Speed Sensor Electrical Connector
    GM860433Courtesy of GENERAL MOTORS CORP.
  10. Install the electrical connector to the speed sensor.
    11. Fig 3: Transfer Case Vent Hose
    GM860435Courtesy of GENERAL MOTORS CORP.
  11. Install the vent hose to the vent tube.
  12. Install the fuel lines to the fuel line bracket.
  13. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement .
  14. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement .
  15. Fill the transfer case with the proper transfer case fluid. Refer to Transfer Case Fluid Replacement .
  16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
RENDER: 1.0x

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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.