How Replace the Transfer Case in a 2000 Suburban

The transfer case is the most important component on a Chevy Suburban with four-wheel drive. It connects the vehicle's two driveshafts and operates the transfer from two- to four-wheel. Overhauling a transfer case is possible, but best left to professionals due to its many small parts. However, it is possible to instead replace the transfer case with a new or previously restored model. This remains a complex task that you should talk with your mechanic about beforehand.

Instructions

Removal

1

Open the hood and disconnect the truck's negative battery cable, loosening the black cable clamp nut with your wrench. Put the transfer case in the two-wheel-drive high position, if the case shifts manually.

2

Raise the truck on its rear end using your floor jack and lower it onto jack stands placed under the frame rails. Working underneath the truck, unbolt and remove any shield panels that are in the vicinity of the driveshaft.

3

Place your drain pan underneath the transfer case. Remove the filler plug at the top of the case using your wrench followed by the drain plug at the bottom, draining the transfer case lubricant into the pan.

4

Mark the front and rear driveshafts where they connect to the transfer case and differential using paint or chalk. Remove all nuts, bolts and straps with your wrench, tape over the universal joint bearing caps with masking tape and then lower and remove the driveshafts.

5

Unplug all of the case's electrical connectors and disconnect the vent hose; these are all along the top of the case. Disconnect the shift linkage from the case's front end -- on a manual case only -- by pulling the linkage ball socket off the pivot on the shift lever.

6

Remove the support braces for the case and transmission using your wrench -- there are braces on the left and right sides of these components.

7

Raise the transmission with a floor jack and then unbolt and remove the mount directly fastening the transmission to the chassis using your wrench. Support the transfer case with another jack.

8

Remove the nuts connecting the transfer case to the transmission or adapter using your wrench and retain the washers. Move the jack and case toward the rear of the truck until it clears the transmission, then lower the jack and remove the case.

Installation

9

Raise the replacement transfer case with the jack and guide it into position, connecting it to the transmission through the input shaft. Apply the case-to-transmission nuts with their washers.

10

Re-install the support braces on the left and right sides of the transmission/transfer case and then lower the jack supporting the transmission.

11

Reconnect the electrical connectors and hoses at the top of the case. Press the shift linkage into position onto the shift lever at the case's front end using the linkage ball socket.

12

Guide and install the front and rear driveshafts into the transfer case and the differential; use the markings you made (Section 1 Step 4) to ensure they are in the proper position. Fasten the driveshafts in place with their straps and bolts using your wrench.

13

Fill the transfer case with 2.3 quarts of Dexron III automatic transmission fluid using a never-before-used syringe bottle inserted into the case's upper fill hole. Some specific transfer cases require a special type of transfer case fluid; check with the vendor/manufacturer.

14

Re-install the shield panels with their bolts and your wrench, the lower the truck off the jack stands using the floor jack.

15

Reconnect the negative battery cable with its cable clamp nut and your wrench.