• If you currently own, previously owned or want to own an Avalanche, we welcome you to become a member today. Membership is FREE, register now!

Manual transfer case swap

Im-dman427

New Member
Joined
Nov 14, 2018
Messages
3
Location
Okanagan, B.C.
I have an 02 avalanche. Like many of you, I'm sure, I've had many problems with the transfer case. This seems to be the weak point of this truck. Finally the fwd driveshaft output bearing has gone. After doing copious amounts of research and coming up with almost nothing, I am going to be doing a manual transfer case swap.
I haven't found anyone else that's done this and posted about it.
I'll keep you posted with a success story (hopefully) and what I've done. I'll try to take pics as I go too.
 
  Check out straight axle swaps.
You tube, here, LS trucks and a Google search.
ms38w & Lord Aries on here
   
 
The swap was easy. It was straight over bolt on for the drive train. Simply remove the driveshafts and skid plate, disconnect 5 connectors, drain the fluid and take off the shifter motor (that often stops working) then undo the 6 nuts, pull it back drop the front end down turn it sideways and shed out. Some transmission fluid will leak out.
A little tip for ya, make sure you have a stubby 15mm combination wrench handy.
After installing the new transfer case I zip tied the selector motor up to the frame to connect the cannon plug to so I can still use the push button for locking the front axle in. I am building a wire harness to connect the position sensor on the front of the new transfer case to the forward axle locking in mechanism so the push button will be completely removed.
I removed the center console then measured the length of the rod that connects to the shifter and drilled a hole through the floor from the bottom into the cabin. I then placed the backing plate from the shifter centered around the hole, marked it out and cut away.
Once the hole was made in the floor I measured and cut out the side of my center console before reinstalling it. I also cut the shifter shaft and nob 1 inch shorter for less cutting on the console.
After filling the new transfer case with ATF I took it for a test drive. It works perfectly. Except...the service 4wd light is on. Hence building a wire harness and I'll be pulling out the 4wd fuses once the harness is in.
 

Great job on the T-case.

  Imgur one I use after photorippoff
There is also Gallery you can use.
 
Back
Top