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Car Nut
Car Nut, Auto Service Technician
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Experience:  Auto Parts, Wheel Interchange, Diagnostics for over 20 Years
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2002 gmc envoy: disengage..transfer case..4x4..towing

Customer Question

need instructions on how to disengage transfer case of my 2002 gmc envoy 4x4 that I will be towing behind my RV. I lost the owner's manual
Submitted: 5 years ago.
Category: Car
Expert:  Car Nut replied 5 years ago.
Let me know if this helps... if not let me know.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable.
  3. Shift the transfer case into the 4HI range.
  4. Drain the transfer case fluid.
  5. Support the transfer case.
  6. Remove or disconnect the following:

    Skid plate
    Front and rear driveshafts from the transfer case. Matchmark the shafts prior to removal.
    Vacuum lines and/or the electrical connectors, as equipped
    Transfer case shift rod/cable from the case, if applicable
    Support brace-to-transfer case bolts, if applicable
    Transfer case

  7. Remove all traces of old gasket material from the mating surfaces.

    Click image to see an enlarged view

    Fig. Transfer case-to-manual transmission mounting



    Click image to see an enlarged view

    Fig. Transfer case-to-automatic transmission mounting


To install:

  1. Install or connect the following:

    New gasket using sealer to hold it in position
    Transfer case. Torque the bolts to 33-35 ft. lbs. (45-47 Nm) on 2001 models.
    Support brace bolts. Torque the bolts to 35-37 ft. lbs. (47-50 Nm), if equipped.
    Shift rod to the case, if equipped
    Vacuum lines and/or electrical connections, as necessary
    Front and rear driveshafts by aligning the matchmarks

  2. Refill the transfer case.
  3. Install or connect the following:

    Skid plate, if equipped
    Negative battery cable


2002-05 Vehicles



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable.
  3. Raise and support the vehicle. Drain the transfer case.
  4. Remove or disconnect the following:

    Fuel tank shield mounting bolts and shield
    Front and rear propeller shaft. Matchmark the shafts prior to removal.
    Fuel lines from the retainer
    Electrical harness from the retainers on the right and left sides
    Speed sensor electrical connectors
    Motor/encoder electrical connector
    Transfer case wiring harness
    Vent hose

  5. Install a transmission jack to support the transfer case.

    Transfer case mounting bolts
    Transfer case from the vehicle
    Transfer case gasket and discard if damaged


To install:

  1. Install or connect the following:
    NOTE
    You must replace the transfer case gasket if it is damaged. Never use silicone sealant in place of, or with the transfer case gasket.






    Transfer case, using a new gasket if necessary
    Transfer case mounting bolts and tighten to 35 ft. lbs. (47 Nm)

  2. Remove the transmission jack.
  3. The remainder of installation is the reverse of removal.
  4. Refill the transfer case.

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