GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Astro - 4WD 🢒 Driveline/Axle 🢒 Transfer Case - NVG 136-NP4 🢒 Transfer Case Motor/Encoder Replacement

Removal Procedure

    Object Number: 648043 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the engine brace mounting bolt.
  3. Remove the engine brace.
  4. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.

    5. Object Number: 648014 Size: SH
  5. Remove the motor/encoder electrical connector.

    6. Object Number: 648008 Size: SH
  6. Remove the motor/encoder mounting bolts.

    7. Object Number: 651492 Size: SH
  7. Remove the motor/encoder assembly.

    8. Object Number: 648015 Size: SH
  8. Remove the motor/encoder gasket.

Installation Procedure

    Object Number: 648015 Size: SH

    Important: If the motor/encoder is going to be replaced, DO NOT use the old gasket. Use the gasket that comes with the motor/encoder.

  1. Install the motor/encoder gasket.

    2. Object Number: 651492 Size: SH

    Important: Ensure the motor/encoder aligns with the detent on the transfer case.

  2. Install the motor/encoder assembly.

    3. Object Number: 648008 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important: Before installing the motor/encoder mounting bolts, make sure that the motor/encoder is flat against the transfer case.

  3. Install the motor/encoder mounting bolts.

    4. Tighten
    Tighten the motor/encoder mounting bolts to 20 N·m (15 lb ft).


    Object Number: 648014 Size: SH
  4. Install the motor/encoder electrical connector.

    5. Object Number: 648043 Size: SH
  5. Install the engine brace.
  6. Install the engine brace mounting bolts.

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

  7. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  8. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.