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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 601 (Transfer Case - NVG 136-NP4 (One Speed Automatic)) >> Repair Instructions >> Transfer Case Disassemble

Transfer Case Disassemble

WARNING: This page is about a different car, the 2001 Oldsmobile Bravada, 2001 GMC Safari, and 2001 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the motor/encoder mounting bolts.
  2. Remove the motor/encoder assembly.
  3. Remove the motor/encoder gasket.
    Fig 1: Removing/Installing Motor/Encoder Assembly
    G01683697
  4. Remove the left rear speed sensor.
  5. Remove the right rear speed sensor.
    Fig 2: Removing/Installing Rear Speed Sensors
    G01683698
  6. Remove the front speed sensor.
    Fig 3: Removing/Installing Front Speed Sensor
    G01683699
  7. Remove the vent tube (only if damaged).
    Fig 4: Removing/Installing Vent Tube
    G01683700
  8. Remove the rubber plug.
    Fig 5: Removing/Installing Rubber Plug
    G01683701
  9. Remove the mounting studs (only if damaged)
    Fig 6: Removing/Installing Mounting Studs
    G01683702
    NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
  10. Remove the front output shaft seal.
    Fig 7: Removing Front Output Shaft Seal
    G01683703
    NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
  11. Remove the input shaft seal.
    Fig 8: Removing Input Shaft Seal
    G01683704
    NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
  12. Remove the rear output shaft seal.
    Fig 9: Removing Rear Output Shaft Seal
    G01683705
  13. Remove the transfer case retaining bolts.
    Fig 10: Removing Transfer Case Retaining Bolts
    G01683706
  14. Insert a flat bladed screwdriver in the slot on the left side of the transfer case.
    Fig 11: Separating Front & Rear Case Halves (1 Of 2)
    G01683707
  15. Insert a flat bladed screwdriver in the slot on the right side of the transfer case
  16. Apply equal pressure on both of the screwdrivers in a downward motion and separate the front and rear case halves.
    Fig 12: Separating Front & Rear Case Halves (2 Of 2)
    G01683708
  17. Insert a pair of snap ring pliers in the slot.
  18. Using the snap ring pliers, open the retaining ring for the rear output shaft bearing.
    Fig 13: Opening Retaining Ring For Rear Output Shaft Bearing
    G01683709
  19. Remove the rear case from the front case.
    Fig 14: Removing Rear Case From Front Case
    G01683710
  20. Remove the oil pump wear sleeve (only if worn or damaged).
    Fig 15: Removing Oil Pump Wear Sleeve
    G01683711
  21. Remove the rear output shaft bearing retaining ring.
    Fig 16: Removing Rear Output Shaft Bearing Retaining Ring
    G01683712
  22. Remove the rear output shaft bearing.
    Fig 17: Removing Rear Output Shaft Bearing
    G01683713
  23. Remove the tone wheel retaining ring.
    Fig 18: Removing Tone Wheel Retaining Ring
    G01683714
  24. Remove the tone wheel.
    Fig 19: Removing Tone Wheel
    G01683715
  25. Remove the oil pump wave spring.
    Fig 20: Removing Oil Pump Wave Spring
    G01683716
  26. Remove the oil pump retaining ring.
    Fig 21: Removing Oil Pump Retaining Ring
    G01683717
  27. Remove the magnet.
    Fig 22: Removing Magnet
    G01683718
  28. Remove the oil pump screen assembly.
    Fig 23: Removing Oil Pump Screen Assembly
    G01683719
  29. Remove the oil pump assembly.
    Fig 24: Removing Oil Pump Assembly
    G01683720
  30. Remove the oil pump pick up tube seal.
    Fig 25: Removing Oil Pump Pick Up Tube Seal
    G01683721
  31. Remove the drive sprocket retaining ring.
    Fig 26: Removing Drive Sprocket Retaining Ring
    G01683722
  32. Remove the driven sprocket retaining ring.
    Fig 27: Removing Driven Sprocket Retaining Ring
    G01683723

    Important:  If the drive chain and sprockets are to be reused, mark the relationship of the drive chain to the sprockets for proper realignment of the wear patterns for the procedure.

  33. Remove the drive chain and sprockets.
    Fig 28: Removing Drive Chain & Sprockets
    G01683724
  34. Remove the mainshaft assembly.
    Fig 29: Removing Mainshaft Assembly
    G01683725
  35. Remove the support bearing retaining ring.
    Fig 30: Removing Support Bearing Retaining Ring
    G01683726
  36. Using a brass drift and a hammer, remove the inner bearing.
  37. Remove the thrust bearing.
  38. Remove the outer support.
    Fig 31: Removing Thrust Bearing & Outer Support
    G01683727

    Important:  DO NOT wash the clutch plates. They can be reused if not damaged or worn.

  39. Remove the clutch pack assembly.
    Fig 32: Removing Clutch Pack Assembly
    G01683728
  40. Remove the inner drum retaining ring.
    Fig 33: Removing Inner Drum Retaining Ring
    G01683729
  41. Remove the inner drum.
    Fig 34: Removing Inner Drum
    G01683730

    Important:  The transfer cases that have a wave spring in thew apply plate are preload transfer case. The transfer cases that have a fingered washer are for transfer cases that are non-load transfer cases.

  42. Remove the inner clutch spring (non-load shown).
    Fig 35: Removing Inner Clutch Spring (Non-Load Shown)
    G01683731
  43. Remove the outer drum assembly.
    Fig 36: Removing Outer Drum Assembly
    G01683732
  44. Remove the poppet assembly.
    Fig 37: Removing Poppet Assembly
    G01683733
  45. Remove the clutch inserts (left side shown).
    Fig 38: Removing Clutch Inserts (Left Side Shown)
    G01683734
  46. Remove the clutch lever assembly.
    Fig 39: Removing Clutch Lever Assembly
    G01683735
  47. Remove the input shaft retaining ring.
    Fig 40: Removing Input Shaft Retaining Ring
    G01683736
  48. Remove the input shaft bearing retaining ring.
    Fig 41: Removing Input Shaft Bearing Retaining Ring
    G01683737
  49. Remove the input shaft assembly.
    Fig 42: Removing Input Shaft Assembly
    G01683738
  50. Remove the input shaft bearing
    Fig 43: Removing Input Shaft Bearing
    G01683739
  51. Remove the front input shaft dust shield.
    Fig 44: Removing Front Input Shaft Dust Shield
    G01683740
  52. Remove the front input shaft retaining ring.
    Fig 45: Removing Front Input Shaft Retaining Ring
    G01683741
  53. Remove the front output shaft assembly.
    Fig 46: Removing Front Output Shaft Assembly
    G01683742
  54. Remove the front output shaft bearing retaining ring.
    Fig 47: Removing Front Output Shaft Bearing Retaining Ring
    G01683743
  55. Remove the front output shaft bearing.
    Fig 48: Removing Front Output Shaft Bearing
    G01683744
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