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Bob, Auto Tech
Category: Chevy
Satisfied Customers: 4087
Experience:  Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
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How to install transfer case motor on 2002 chevy Avalanche

Resolved Question:

How to install transfer case motor on 2002 chevy Avalanche 4x4
Submitted: 9 years ago.
Category: Chevy
Expert:  Bob replied 9 years ago.

Sending you instructions for the transfer case encoder motor, right out of the Avalanche service manual from GM. Thanks

Transfer Case Motor/Encoder Replacement

Removal Procedure

    Object Number: 715660  Size: SH

  1. Raise and suitably support the vehicle.
  2. Remove the transfer case shield.
  3. Remove the front propeller shaft.
  4. Remove the motor/encoder electrical connectors.
    Object Number: 662850  Size: SH

  5. Remove the motor/encoder mounting bolts.
  6. Remove the motor/encoder assembly.
  7. Remove the motor/encoder gasket.

Installation Procedure

    Object Number: 804163  Size: SH


    If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary.
    When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and it is flat against the transfer case before tightening the mounting bolts.

  1. Install the NEW motor/encoder gasket to the transfer case.
  2. Install the motor/encoder to the transfer case.

    Notice: 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 motor/encoder mounting bolts.

    Tighten the bolts, in the sequence shown, to 20 N·m (15 lb ft).

    Object Number: 715660  Size: SH

  4. Install the motor/encoder electrical connector. Ensure that the retention clips activate.
  5. Install the front propeller shaft.
  6. Install the transfer case shield .
  7. Lower the vehicle.
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