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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - NVG 136-NP4 >> Repair Instructions >> Transfer Case Assembly Replacement >> Removal Procedure

Removal Procedure

  1. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General information.
  2. Remove the engine brace mounting bolts.
  3. Remove the engine brace.
    Fig 1: Engine Brace
    G01643254Courtesy 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 in Propeller Shaft.
  6. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - FRONT in Propeller Shaft.
  7. Remove the motor/encoder electrical connector.
    Fig 2: Motor/Encoder Electrical Connector
    G01643255Courtesy of GENERAL MOTORS CORP.
  8. Remove the transfer case electrical wiring harness.
    Fig 3: Transfer Case Electrical Wiring Harness
    G01643256Courtesy of GENERAL MOTORS CORP.
  9. Remove the transfer case vent hose.
    Fig 4: Transfer Case Vent Hose
    G01643257Courtesy of GENERAL MOTORS CORP.

    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. Support the transmission with a suitable transmission jack.
  11. Remove the transmission mount retaining nuts.
    Fig 5: Transmission Mount Retaining Nuts
    G01643258Courtesy 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 Bolts
    G01643259Courtesy of GENERAL MOTORS CORP.
  13. Remove the transmission mount assembly.
    Fig 7: Transmission Mount Assembly
    G01643260Courtesy of GENERAL MOTORS CORP.
  14. Remove the transfer case bottom retaining nut.
    Fig 8: Transfer Case Bottom Retaining Nut
    G01643261Courtesy of GENERAL MOTORS CORP.

    Important:  The transmission mount must be replaced in it's 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 Nuts
    G01643262Courtesy of GENERAL MOTORS CORP.
  18. Install the transmission jack to the transfer case.
  19. Remove the transfer case assembly.
    Fig 10: Installing Transmission Jack To Transfer Case
    G01643263Courtesy of GENERAL MOTORS CORP.

    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 11: Transfer Case Gasket
    G01643264Courtesy of GENERAL MOTORS CORP.
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