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Home >> Chevrolet >> 2004 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - NVG 136-NP4 >> Repair Instructions >> Transfer Case Assembly Replacement >> Installation Procedure

Installation Procedure

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.
    Fig 1: View Of Transfer Case Gasket
    GM654219Courtesy of GENERAL MOTORS CORP.
  2. Install the transfer case assembly.
    Fig 2: Supporting Transfer Case With Transmission Jack
    GM648037Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the transfer case retaining nuts.

    Tighten:  Tighten the transfer case retaining nuts to 55 N.m (40 lb ft).

    Fig 3: Identifying Transfer Case Upper Retaining Nuts
    GM648011Courtesy of GENERAL MOTORS CORP.
  4. Remove the transmission jack from the transfer case.
  5. Install the transmission jack to the transmission.
  6. Install the transmission mount.
    Fig 4: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission mount bolts.

    Tighten:  Tighten the transmission mount bolts 47 N.m (35 lb ft).

    Fig 5: Locating Transmission Mount Bolts
    GM647998Courtesy of GENERAL MOTORS CORP.
  8. Lower the transmission into place.
  9. Remove the transmission jack stand.
  10. Install the transmission mount retaining nuts.

    Tighten:  Tighten the transmission mount retaining nuts to 40 N.m (29 lb ft).

    Fig 6: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  11. Install the motor/encoder electrical connector.
    Fig 7: Identifying Motor/Encoder Electrical Connector
    GM648014Courtesy of GENERAL MOTORS CORP.
  12. Install the transfer case electrical wiring harness.
    Fig 8: View Of Transfer Case Electrical Wiring Harness
    GM647994Courtesy of GENERAL MOTORS CORP.
  13. Install the transfer case vent hose.
    Fig 9: Locating Transfer Case Vent Hose
    GM715667Courtesy of GENERAL MOTORS CORP.
  14. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft.
  15. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  16. Install the engine brace.
  17. Install the engine brace mounting bolts.

    Tighten:  Tighten the engine brace mounting bolts to 50 N.m (37 lb ft).

    Fig 10: Locating Engine Brace Mounting Bolt
    GM648043Courtesy of GENERAL MOTORS CORP.
  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. Refer to Lifting and Jacking the Vehicle in General Information.
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