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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 >> 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.
    Fig 1: Locating Engine Brace Mounting Bolt
    GM648043Courtesy of GENERAL MOTORS CORP.
  3. Remove the engine brace.
  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: Identifying Motor/Encoder Electrical Connector
    GM648014Courtesy of GENERAL MOTORS CORP.
  8. Remove the transfer case electrical wiring harness.
    Fig 3: View Of Transfer Case Electrical Wiring Harness
    GM647994Courtesy of GENERAL MOTORS CORP.
  9. Remove the transfer case vent hose.
    Fig 4: Locating Transfer Case Vent Hose
    GM715667Courtesy 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: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Raise the transmission assembly enough to clear the rear crossmember.
  12. Remove the transmission mount bolts.
    Fig 6: Locating Transmission Mount Bolts
    GM647998Courtesy of GENERAL MOTORS CORP.
  13. Remove the transmission mount assembly.
    Fig 7: View Of Transmission Mount
    GM648001Courtesy of GENERAL MOTORS CORP.
  14. Remove the transfer case bottom retaining nut.
    Fig 8: View Of Transfer Case Bottom Retaining Nut
    GM648003Courtesy 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: Identifying Transfer Case Upper Retaining Nuts
    GM648011Courtesy of GENERAL MOTORS CORP.
  18. Install the transmission jack to the transfer case.
    Fig 10: Supporting Transfer Case With Transmission Jack
    GM648037Courtesy of GENERAL MOTORS CORP.
  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 11: View Of Transfer Case Gasket
    GM654219Courtesy of GENERAL MOTORS CORP.
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