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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 >> Removal Procedure

Removal 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.
  1. Raise the vehicle.
  2. Remove the engine brace mounting bolts.
  3. Remove the engine brace.
    4. Fig 1: Engine Brace
    G02502206Courtesy of GENERAL MOTORS CORP.
  4. Remove the transfer case shield. Refer to Transfer Case Shield Replacement .
  5. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR .
  6. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT .
  7. Remove the motor/encoder electrical connector.
    Fig 2: Motor/Encoder Electrical Connector
    G02502207Courtesy of GENERAL MOTORS CORP.
  8. Remove the transfer case electrical wiring harness.
    Fig 3: Transfer Case Electrical Wiring Harness
    G02502208Courtesy of GENERAL MOTORS CORP.
  9. Remove the transfer case vent hose.

    Important:  To perform the following service procedure, the transmission mount must be removed to gain access to the bottom retaining nut of the transfer case. Do not support the transmission by the oil pan.

    10. Fig 4: Transfer Case Vent Hose
    G02502209Courtesy of GENERAL MOTORS CORP.
  10. Support the transmission with a suitable transmission jack.
  11. Remove the transmission mount retaining nuts.
    Fig 5: Transmission Mount Retaining Nut
    G02502210Courtesy of GENERAL MOTORS CORP.

    Important:  Raise the transmission assembly enough to clear the rear crossmember.

  12. Remove the transmission mount bolts.
    Fig 6: Transmission Mount Bolt
    G02502211Courtesy of GENERAL MOTORS CORP.
  13. Remove the transmission mount assembly.
    Fig 7: Transmission Mount Assembly
    G02502212Courtesy of GENERAL MOTORS CORP.
  14. Remove the transfer case bottom retaining nut.
    Fig 8: Transfer Case Bottom Retaining Nut
    G02502213Courtesy of GENERAL MOTORS CORP.

    Important:  The transmission mount must be replaced in its original position to support the transmission. When reinstalling the transmission mount, it is not necessary reinstall the mounting nuts and bolts. The weight of the transmission and engine will hold the transmission mount in place until this service procedure is completed.

  15. Install the transmission mount.
  16. Remove the transmission jack stand from the transmission.
  17. Remove the transfer case upper retaining nuts.
    Fig 9: Transfer Case Upper Retaining Nut
    G02502214Courtesy of GENERAL MOTORS CORP.
  18. Install the transmission jack to the transfer case.
  19. Remove the transfer case assembly.

    Important:  DO NOT reuse the old gasket if it is damaged. DO NOT use any type of sealer in place of the gasket.

  20. Remove the transfer case gasket.
    Fig 10: Transfer Case Gasket
    G02502216Courtesy of GENERAL MOTORS CORP.
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