DORMAN 600-902 Transfer Case Motor Instruction Manual
- June 1, 2024
- DORMAN
Table of Contents
600-902
INSTALL/REMOVAL INSTRUCTIONS: TRANSFER CASE MOTOR
600-902 Transfer Case Motor
ATTENTION: Refer to the appropriate shop manual for your vehicle to
obtain specifi c service procedures for this part. If you do not have a
service manual or lack the skill to install this part, it is recommended that
you seek the services of a qualifi ed technician. Pay special attention to all
cautions and warnings included in the shop manual. Read and follow all
instructions carefully.
REMOVAL/INSTALL OF TRANSFER CASE MOTOR (600-902)
2000–1996 Chevrolet K2500 Pickup, 1999–96 Chevrolet K1500 Pickup/Surburban/
Tahoe, 1999 Cadillac Escalade, 2002–01 Dodge Durango/Dakota, 1999–96 GMC Yukon
General Tech Tips:
- Check that the vehicle 4WD and Automatic Transfer Case (ATC) fuses have not blown.
- Road test vehicle and document any noises and symptoms of unusual operation.
- Attach scan tool to diagnostic data link connector and retrieve any stored trouble codes including pending codes and freeze frame data.
- Check for any related Technical Service bulletins.
- Check for proper transfer case I.D. by referencing the tag that is attached to the transfer case extension housing. This tag is bolted on and may include the model number, serial number, build date and range reduction ratio.
IMPORTANT
THIS TRANSFER CASE MOTOR IS SHIPPED IN THE 2WD HIGH POSITION
Removal Instructions
STEP 1: This Transfer Case motor is shipped with a plastic alignment insert
which has positioned the unit into the transfer case 2WD High position. Place
the transfer case into the 2WD High position, before removal of the transfer
case motor. If the transfer case is unable to be shifted into the 2WD High
position beforehand, please use the procedure outlined in the installation
section below.
STEP 2: Raise vehicle on a lift or jack stands making sure the vehicle is
properly and safely supported.
STEP 3: Remove transfer case shield if vehicle is equipped with one.
STEP 4: If motor cannot be accessed because of front driveshaft – remove the
driveshaft following the procedure in the shop manual. Check the universal
joints at this time and replace if faulty.
STEP 5: If motor still cannot be removed due to interference with the yoke –
remove the yoke by removing the nut holding the yoke to the transfer case. Pay
attention to the position of any washers. Remove the yoke being careful not to
damage the seal. Inspect the seal and replace if necessary.
STEP 6: Disconnect the shift motor electrical connector(s) by lifting up the
plastic retaining tab and pulling apart. Be careful not to break off the
plastic connecting tabs.
STEP 7: Remove the three or four bolts that attach the motor to the transfer
case.
STEP 8: Remove the transfer case motor from the transfer case.
Installation Instructions
STEP 1: Clean mounting surface on the transfer case making sure that there is
no gasket material or residue left from the motor removal.
STEP 2: Remove the plastic alignment insert from the new motor.
STEP 3: Look at the position of the transfer case shaft and see if it matches
up with the receiving end of the transfer case motor.
If it does not – it may be necessary to manually turn the shift shaft on the
transfer case with a crescent wrench to align it with the motor.
For this transfer case motor the transfer case should be in the 2WD High
position for installation.
STEP 4: Do not attempt to align the motor to the transfer case by turning the
drive opening in the motor with a half inch drive ratchet or other tool.
Damage to the motor may occur if this procedure is used.
STEP 5: Do not attempt to put power to the transfer case motor to move the
receiving end for alignment. Doing so may lead to internal motor damage.
STEP 6: Once the motor is indexed properly to the transfer case – install
motor by holding it fl at against the transfer case and thread in the mounting
bolts Start the mounting bolts by hand to avoid cross threading. Snug the
bolts up evenly. If any binding occurs while tightening the bolts – remove
them and make sure that the motor is fully seated on the shaft and lying fl at
against the transfer case.
STEP 7: Torque the mounting bolts to approximately 15 FT LBS or 20 NM. Consult
service manual for exact specifi cation.
STEP 8: Connect the electrical connectors ensuring a tight fi t. Make sure the
wires are routed correctly and secured to the transfer case or vehicle where
required.
STEP 9: Install the yoke making sure not to nick or damage the seal. Install
any washers that came off in the proper order and orientation.
STEP 10: Install the nut and torque to the proper specifi cation. New Venture
gear cases – 110 FT LBS.
STEP 11: Install the drive shaft and torque the bolts that hold the universal
joint to the proper specifi cation.
STEP 12: Install the transfer case shield.
STEP 13: Check the transfer case oil level and add oil if necessary.
STEP 14: Lower vehicle and test for proper 4WD operation.
STEP 15: Clear any stored diagnostic trouble codes that were related to the
repair.
We appreciate your opinions regarding this product!
Please call our Technical Assistant with any challenges or suggestions
regarding the installation or operation of this product.
1-800-523-2492
Disclaimer:
Even though every attempt is made to ensure this information is complete and
accurate, it is impossible to account for all possible circumstances or
situations. Please consult with a qualifi ed auto technician before attempting
to perform any work you are not qualifi ed to do. Automobiles can be hazardous
to work on; be sure to take all necessary safety precautions. Failure to do so
may result in property damage or personal injury. Certain motor vehicle
standards and performance requirements may apply to your motor vehicle (such
as Federal Motor Vehicle Safety Standards by the National Highway Traffi c
Safety Administration). Be sure that your work is performed in accordance with
such standards and that you do not disable any motor vehicle safety feature.
©2012 Dorman Products, Inc.
No reproductions in whole or in part without prior written approval.
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