Transfer Case Description and Operation: Notes

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

The New Venture Gear (NVG) 261, RPO NP2 transfer case is a two-speed, part-time with "mode shift-on-the-fly" capability. It has a chain driven front output shaft and an epicyclical low range planetary arrangement. The NVG 261 transfer case features a four position shift lever control located in the vehicle floor plan. As required, the operator can select 4HI position from 2HI "on-the-fly," as described in the owners manual. A dash 4WD lamp continues flashing during shifting, until all criteria have been met and the new mode/range position has been reached. Once the new mode/range position is fully engaged and the front axle disconnect locks in, the dash light 4WD indicator lamp remains ON constantly. Range shifting functions similarly, although it should be limited to speeds 5 km/h (3 mph) or less.

The four manual mode, or range gear positions, of the NVG 261 transfer case are:

2HI - 2 wheel drive high range
4HI - 4 wheel drive high range, part-time
4LO - 4 wheel drive low range, 2.72:1 gear ratio reduction
N - Neutral, 4 wheel

When the ignition switch is placed in the run position and the 4WD shift lever is in the 4WD position, the transfer case switch closes, supplying a ground to the axle actuator control circuit. With the ground applied, the logic of the front axle actuator actuates a DC motor to engage the front axle and supply voltage to the axle switch signal circuit. The axle switch signal circuit notifies the powertrain control module (PCM) and the Anti-Lock Brake System that the vehicle is in the 4WD mode. The 4WD indicator is commanded on via a Class 2 serial data signal from the PCM. When the 4WD shift lever is in the 4WD low range position, the transfer case switch closes and supplies a ground on the 4WD low signal circuit. This informs the PCM that the vehicle transfer case is in low range. When the vehicle is in low range, the PCM changes the shift pattern of the automatic transmission.

During normal driving situations, the transfer case can operate in the 2WD mode. The driver may choose to select any of the mode/range gear positions while driving the vehicle. However, the transfer case should not be shifted into or out of 4LO unless the following criteria have been met:

The automatic transmission is in neutral or the clutch pedal is depressed.
The vehicle speed is less than 5 km/h (3 mph).

This transfer case also has a neutral position. A shift to the neutral position allows the vehicle to be towed without rotating the transmission output shaft. In the neutral position, the rear propeller shaft rotates the transfer case rear output shaft, in turn rotating the oil pump, providing constant lubrication during towing. Note, this neutral position is a 4WD neutral, meaning the front and rear outputs of the transfer case are engaged as though in 4HI. With a disconnecting front axle, there is no power flow to the front wheels, allowing towing with the front wheels off the ground or flat towing without driveline binding. Again, the transfer case should not be shifted into or out of neutral unless the following criteria have been met:

The automatic transmission is in neutral or the clutch pedal is depressed.
The vehicle speed is less than 5 km/h (3 mph).

The NVG 261 transfer case is available in 5 variations, depending on the engine and transmission configurations. The variations allow the transfer case to handle different torque loads. When servicing the transfer case it is important to understand which variation is being serviced because of the difference in parts.

NVG 261 Variations

Model	Transmission	Input Gear	Output Shaft	Chain Size	Hi/Low Planetary	Application
Light Duty (LD)	M30 - 4L60E	27T Spline	32T Spline	3/8 X 1.25 in	3 Pinion	K1
Light Duty (LD)	MG5 - NV 3500	32T Spline	32T Spline	3/8 X 1.25 in	3 Pinion	K1
Heavy Duty 1 (HD1)	MT1 - 4L80E MW3 - NV 4500	32T Spline	32T Spline	3/8 X 1.5 in	6 Pinion	K2 Non Heavy Duty
Heavy Duty 2 (HD2)	MT1 - 4L80E MW3 - NV 4500	32T Spline	32T Spline	7/16 X 1.5 in	6 Pinion	K2 Heavy Duty
Super Heavy Duty (SHD)	ML6 - ZF S6-650 M74 - Allison	29T Spline	31T Spline	7/16 X 1.5 in	6 Pinion	K3

The SHD model shares many of the same components, but the increased torque capacity of the SHD requires a double row input bearing and larger diameter rear output shaft, rear output shaft bearing higher capacity, larger rear seal and case halves machined differently.

The following changes were made to the NVG 261 for this model year:

The case half bolts now use a cup style aluminum washer, which allow using the bolts again.
On the light duty version, the planetary carrier has been changed from a 4 pinion gear to a 3 pinion gear design.
The bearing is changed to a bushing in the shift control lever shaft support.
The rear output shaft is machined differently at the retaining ring groove for the synchronizer retaining ring and the retaining ring is now a smaller diameter.