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Transfer Case - Nvg 263-NP1 (Selectable): Removal & Installation GMC Sierra 2500

Transfer Case 12 illustrations ~1496 words

Installation Procedure

  1. Install the transfer case shield to the transmission support.
  2. Install the transfer case shield mounting bolts. Tighten the transfer case shield mounting bolts to 20 N.m (15 lb ft).
  3. Lower the vehicle.

Removal Procedure

Important: When performing the following service procedures, use only hand tools in order to remove and install the fill or drain plugs. Always start the plugs by hand in order to prevent cross threading.

Scheme 246

Scheme 246: Removal Procedure
Scheme 246: Removal Procedure

Scheme 247

Scheme 247
Scheme 247
  1. Raise the vehicle.
  2. Remove the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  3. Remove the transfer case fill plug.
  4. Remove the drain plug from the transfer case.

Important: If the transfer case drain or fill plug have to be replaced, used only aluminum replacement drain plugs. Steel plugs will react with the magnesium of the transfer case.

  1. Install the transfer case drain plug. Tighten the transfer case drain plug to 20 N.m (15 lb ft).
  2. Fill the transfer case to the bottom of the fill hole with the approved fluid.
  3. Install the transfer case fill plug. Tighten the transfer case fill plug to 20 N.m (15 lb ft).
  4. Install the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  5. Lower the vehicle.

Scheme 248

Scheme 248: Removal Procedure
Scheme 248: Removal Procedure

Scheme 249

Scheme 249
Scheme 249
  1. Raise and suitably support the vehicle.
  2. Remove the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  3. Remove the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-175687-S01230655242005042600000) .
  4. Remove the motor/encoder electrical connector.
  5. Remove the motor/encoder mounting bolts.
  6. Remove the motor/encoder unit from the transfer case.
  7. Remove the motor/encoder silicone gasket.

Important

  1. If the motor/encoder assembly is being replaced because it is defective, make sure that the transfer case is in the neutral position. Manually shift the unit at the shift shaft. Use a crescent wrench if necessary.
  2. If the motor/encoder is being replaced, a new gasket will come with the motor/encoder. DO NOT use the old gasket.
  1. Install the motor/encoder gasket to the transfer case. Important: When installing the motor/encoder unit to the transfer case, make sure that the transfer case is indexed properly and is flat against the transfer case before tightening the mounting bolts.
  2. Install the motor/encoder to the transfer case.
  3. Install the motor/encoder mounting bolts. Tighten the bolts, in the sequence shown, to 20 N.m (15 lb ft).
  4. Install the motor/encoder electrical connector. Ensure that the retention clips activate.
  5. Install the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-175687-S01230655242005042600000) .
  6. Install the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  7. Lower the vehicle.

Scheme 250

Scheme 250: Removal Procedure
Scheme 250: Removal Procedure

Scheme 251

Scheme 251
Scheme 251
  1. Raise the vehicle.
  2. Remove the transfer case speed sensor electrical connector.
  3. Remove the transfer case speed sensor.
  1. Install the transfer case speed sensor. Tighten the transfer case speed sensor to 15 N.m (11 lb ft).
  2. Install the transfer case speed sensor electrical connector.
  3. Lower the vehicle.

Scheme 252

Scheme 252: Removal Procedure
Scheme 252: Removal Procedure

Scheme 253

Scheme 253
Scheme 253
  1. Remove the IP trim bezel.
  2. Pull out the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in order to disconnect the electrical connectors.
  3. Disconnect all the electrical connectors from the lamp switch, cargo lamp and 4WD shift buttons assembly.
  4. Remove the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly from the vehicle.
  5. Remove the electrical harness retainer from the IP support beam.
  6. Disconnect the 2 electrical connectors from the transfer case shift control module.
  7. Move the electrical harness to the left side in order to make room to turn the transfer case shift control module.
  8. Rotate the transfer case shift control module about 45 degrees counter clockwise while pulling out at the same time until the module is approximately 90 degrees from the original position.
  9. Pull out the module from the vehicle.
  1. Move the electrical harness to the left side in order to make room to install the transfer case shift control module.
  2. Install the transfer case shift control module so that the electrical connector ports are to the right or pointing towards the instrument cluster.
  3. While installing the transfer case shift control module rotate clockwise until the module is in place and the electrical connector ports are facing outwards.
  4. Install the electrical harness retainer to the IP support beam.
  5. Connect the 2 electrical connectors to the transfer case shift control module.
  6. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly the vehicle.
  7. Connect all the electrical connectors to the lamp switch, cargo lamp and 4WD shift buttons assembly.
  8. Install the lamp switch, 4WD shift buttons, cargo lamp and air deflector louver assembly in place.
  9. Install the IP trim bezel.
  10. Start the engine and test the automatic transfer case system for proper shift operation.

Scheme 254

Scheme 254: Removal Procedure
Scheme 254: Removal Procedure

Scheme 255

Scheme 255
Scheme 255
  1. Remove the instrument panel bezel trim piece.
  2. Pull the tabs on the side of the transfer case drive control switch out.
  3. Pull the transfer case driver control switch straight out from the panel.

Important: Make sure that the transfer case control switch is seated properly in the instrument panel before installing the instrument panel trim bezel.

  1. Install the transfer case driver control switch into the instrument panel.
  2. Install the instrument panel trim bezel.
  1. Install the J 43484 (2) to the J 8092 (1).
  2. Install the transfer case front output shaft seal on the J 43484 (2).
  3. Using the J 43484 (2) and the J 8092 (1), install the transfer case front output seal.
  4. Install the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-175687-S01230655242005042600000) .
  5. Check the transfer case fluid level. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  6. Install the transfer case shield. Refer to «Transfer Case Fluid Replacement»(ref-175704-S06464541342005042700000) .
  7. Lower the vehicle.

Important: The following installation procedure must be performed with the assistance of another technician.

  1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
  2. Rotate the transfer case so that it is in line with the transfer case adapter.
  3. Install the transfer case to the transfer case adapter.
  4. Install the transfer case retaining nuts. Tighten the transfer case retaining nuts to 50 N.m (36 lb ft).
  5. Install the transmission mount assembly.
  6. Install the transmission mount bolts. Tighten the transmission mount bolts to 47 N.m (34 lb ft).
  7. Install the transmission support to the frame.
  8. Install the transmission support mounting bolts. Tighten the transmission support mounting bolts to 70 N.m (51 lb ft).
  9. Lower the transmission/transfer case assembly to the transmission support.
  10. Install the transmission mount retaining nuts. Tighten the transmission mount retaining nuts to 40 N.m (29 lb ft).
  11. Remove the transmission jack stand.
  12. Install the transfer case speed sensor electrical connector.
  13. Install the electrical connector to the motor/encoder.
  14. Install the transfer case vent hose.
  15. Install the transmission shift control cable to the transfer case.
  16. Install the rear propeller shaft. For vehicles equipped with the one piece propeller shaft, refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-175687-S13666381282005042600000) . For vehicles equipped with the two piece propeller shaft, refer to «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-175687-S33480821712005042600000) .
  17. Install the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-175687-S01230655242005042600000) .
  18. Fill the transfer case with the approved fluid. Refer to «Transfer Case Fluid Replacement»(ref-175704-S06464541342005042700000) .
  19. Install the transfer case shield. Refer to «Transfer Case Shield Replacement»(ref-175704-S30724250892005042700000) .
  20. Lower the vehicle.

Important: When installing the input shaft seal, make sure that the part numbers on the seal are facing away from the transfer case assembly. The input shaft seal should be even with the surface of the transfer case after installation.

  1. Position the transfer case input seal on the input shaft.
  2. Using the J 42738, install the input shaft seal in the transfer case.
  3. Install the transfer case assembly.
  4. Check the transfer case fluid level. Refer to «Transfer Case Fluid Replacement»(ref-175704-S06464541342005042700000) .
  5. Lower the vehicle.

Scheme 256

Scheme 256: Removal Procedure
Scheme 256: Removal Procedure

Scheme 257

Scheme 257
Scheme 257
  1. Raise the vehicle.
  2. Remove the transfer case assembly. Refer to «Transfer Case Assembly Replacement»(ref-175704-S26059916332005042700000) .
  3. Support the transmission with a suitable jack stand.
  4. Remove the transfer case adapter mounting bolts.
  5. Remove the transfer case adapter assembly.
  6. Remove the transfer case adapter seal.
  7. Remove the gasket from the transfer case.

Important: Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the O-ring.

  1. Install the new transfer case adapter seal. Important: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.
  2. Install the transfer case adapter.
  3. Install the transfer case adapter mounting bolts. Tighten the transfer case adapter mounting bolts to 50 N.m (36 lb ft). Important: When installing the gasket to the adapter, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing to the top of the transfer case.
  4. Install the new transfer case gasket.
  5. Install the transfer case assembly.
  6. Check the fluid level of the transfer case. Refer to «Transfer Case Fluid Replacement»(ref-175704-S06464541342005042700000) .
  7. Lower the vehicle.

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