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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 767 (Transfer Case - NVG 136-NP4 (1-Speed Automatic)) >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.

Important:  Make sure that the locating tab on the gasket is in the proper location. The locator tab should be facing up.

  1. Install a new transfer case gasket.
  2. Install the transfer case assembly.
  3. Install the transfer case retaining nuts. Tighten the transfer case retaining nuts to 55 N.m (40 lb ft).
  4. Remove the transmission jack from the transfer case.
  5. Install the transmission jack to the transmission.
  6. Install the transmission mount.
  7. Install the transmission mount bolts. Tighten the transmission mount bolts 47 N.m (35 lb ft).
  8. Lower the transmission into place.
  9. Remove the transmission jack stand.
  10. Install the transmission mount retaining nuts. Tighten the transmission mount retaining nuts to 40 N.m (29 lb ft).
  11. Install the motor/encoder electrical connector.
  12. Install the transfer case electrical wiring harness.
  13. Install the transfer case vent hose.
  14. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR .
  15. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT .
  16. Install the engine brace.
  17. Install the engine brace mounting bolts. Tighten the engine brace mounting bolts to 50 N.m (37 lb ft).
  18. Inspect the transfer case fluid level. Refer to Transfer Case Fluid Replacement .
  19. Install the transfer case shield. Refer to Transfer Case Shield Replacement .
  20. Lower the vehicle.
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