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Detailed internal diagram of the 2004 Chevrolet button shift transfer case

Yeah. Need to change my location on the forum. This is fantastic considering I'm on a 1 grand a month fixed income from my VA check with nary a f'in job in sight here in fallon or even in fernley.

We found this tonight. Looked underneath everything every time we stopped and everything was fine, so this occurred very recently.... as in, we didn't even have a drip under the truck where we parked it after coming in yesterday from our mini vacation slash shakedown run with the new (to us, 1981 manufacture) 5th wheel. I'm actually going to go down the street and look in the road to see if I find the pieces. We saw fluid bigtime on the ground and it was pissin like a racehorse in the back driveway, so once it stopped splashing (since it's not like I can go abracadbra stop leaking you SOB) I went underneath... then sent the wife under to take a gander and she took that picture for me.

Think Merchant Automotive would take a rifle in trade? LOLOL
 
Hi Ranger

Is this a 2500 / 2500 hd ?
What kind of trnsfercase is it: NVG 149NP3 - 246NP8 - 261NP2 - 263NP1

i have info on those
 
did something internal cause that?

cause if it's just the case there is an upgraded case available...only $235

link

attachment.php


attachment.php


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NP261XHD/263XHD Rear Heavy Duty Aluminum Transfer Case Half
​
Fits all GM with NP261/263XHD transfer cases ​
Magnesium transfer cases are soft & aluminum pumps are harder so these units have a problem with the pumps wearing into the rear case half & causing a small hole & leak that will ruin your transfer case. Simply replacing the rear case with a factory magnesium case will not solve the problem. This heavy duty aluminum rear case will replace the problematic OEM case & your problems with pump wear will be a thing of the past! This exclusive heavy duty rear case half will replace the magnesium OEM case with no special modifications. This heavy duty aluminum case does not require as pump wear plate or case saver. Includes new bushing.
​
 
Yeah, best thing I can guess is when the case stopped going into 4x, that the fork itself broke off IN the case and just stayed out of the way until our shakedown trip with the trailer.

*I* heard, wife didn't hear, an odd whining noise.

Stopped, nothing found, no drips.... then on the way back from Pahrump to where we're at now, it (the noise) stopped.

Get home, find that.

so, best guess is broken piece finally moved into position and interfaced with the chain, self clearance-ing once it got to a point it couldn't move past and got forced out through the side.

I already have a replacement rear half from merchant, it's just a matter of getting it all out from under the truck in the driveway, in nevada, in late summer where the tools left in the sun as you change from socket to socket will burn your damn hands.



Suburbank2500.... 2004 crew cab duramax, ie 2500hd, pushbutton transfer case.
 
Ahh...I see...I didn't think you had the case half yet, so I was pointing out that there was something better than the GM case half...

Hope it's just the fork and you don't have anything else tore up...
 
Transfer case overhaul NVG - 261-NP2

Her we go, its a lof of documents, hope its eadeable.
I can also send it on a mail to you if you like.
 

Attachments

  • Fig. 1_ Transfer Case Components diasembled view.pdf
    79.4 KB · Views: 47
  • Fig. 2_ Internal Components Disassembled view.pdf
    64.9 KB · Views: 51
  • Fig. 3_ Mounting J 45759 To Transfer case.pdf
    89 KB · Views: 27
  • Fig. 6_ Removing Rear Output Shaft seal.pdf
    30.2 KB · Views: 22
  • Fig. 7_ Removing The Rear Output shaft bearing using J 45380.pdf
    67.3 KB · Views: 22
  • Fig. 8_ Identifying Access Hole plug.pdf
    69.6 KB · Views: 14
  • Fig. 9_ View Of Vehicle Speed Sensor O-ring seal.pdf
    75.8 KB · Views: 17
  • Fig. 10_ Removing Gear Indicator switch.pdf
    91.4 KB · Views: 15
  • Fig. 11_ Identifying Vent Tube elbow.pdf
    59.6 KB · Views: 14
  • Fig. 12_ Locating Shift Control lever bolt.pdf
    77.7 KB · Views: 17
  • Fig. 13_ View Of Case Half Bolt or studs & alu washers.pdf
    50.1 KB · Views: 15
  • Fig. 14_ Locating Slot On Left side of transfer case.pdf
    29.8 KB · Views: 14
  • Fig. 15_ Locating Slot On Right side of transfer case.pdf
    22.5 KB · Views: 14
  • Fig. 16_ Opening Rear Output Shaft bearing outside retaining ring with snap ring pliers.pdf
    58.2 KB · Views: 17
  • Fig. 17_ View Of Rear Case & Front case halves.pdf
    38.1 KB · Views: 18
  • Fig. 18_ Locating Rear Output Shaft bearing retaining ring.pdf
    37.2 KB · Views: 11
  • Fig. 19_ Installing Rear Output shaft bearing.pdf
    33.2 KB · Views: 18
  • Fig. 20_ Identifying Speed Reluctor wheel.pdf
    33.8 KB · Views: 16
  • Fig. 21_ View Of Oil Pump Assembly.pdf
    47.6 KB · Views: 16
  • Fig. 22_ Identifying Transfer Case magnet.pdf
    40.9 KB · Views: 13
Part2
 

Attachments

  • Fig. 23_ Locating Oil Pump.pdf
    36.2 KB · Views: 13
  • Fig. 24_ View Of Oil Pump Suction pipe o-ring.pdf
    22.9 KB · Views: 14
  • Fig. 25_ Locating Shift Fork Shaft spring.pdf
    59.7 KB · Views: 15
  • Fig. 26_ Identifying Driven Sprocket retaining ring.pdf
    49.1 KB · Views: 16
  • Fig. 27_ View Of Drive Sprocket retaining ring.pdf
    39.8 KB · Views: 17
  • Fig. 28_ Locating Drive Chain & sprockets.pdf
    37.3 KB · Views: 17
  • Fig. 29_ Identifying 2_4 Wheel drive syncronizer gear.pdf
    61.3 KB · Views: 13
  • Fig. 30_ View Of Rear Output Shaft assembly.pdf
    34.2 KB · Views: 14
  • Fig. 31_ Identifying Synchronizer retainer ring.pdf
    44.4 KB · Views: 12
  • Fig. 32_ View Of Synchronizer Assembly components.pdf
    69.5 KB · Views: 14
  • Fig. 33_ Locating Drive Sprocket sleeve.pdf
    26.1 KB · Views: 12
  • Fig. 34_ Exploded View Of Synchrinizer assembly.pdf
    58.7 KB · Views: 15
  • Fig. 35_ Identifying Shift Detent bolt.pdf
    23.3 KB · Views: 11
  • Fig. 36_ View Of Shift Shaft.pdf
    48.6 KB · Views: 14
  • Fig. 37_ Identifying High_Low Shift fork on high_low range sleeve.pdf
    22.2 KB · Views: 11
  • Fig. 38_ Locating Input Shaft Seal.pdf
    40.9 KB · Views: 10
  • Fig. 39_ View Of Outer Retaining ring for the input gear bearing.pdf
    53.3 KB · Views: 11
  • Fig. 40_ Removing High_Low Planetary carrier.pdf
    46.7 KB · Views: 11
  • Fig. 41_ Identifying Input Gear retaining ring.pdf
    40.3 KB · Views: 12
  • Fig. 42_ View Of Planetary Carrier lock plate.pdf
    40.7 KB · Views: 14
part3
 

Attachments

  • Fig. 43_ Locating Planetary Carrier front trust washer.pdf
    37 KB · Views: 12
  • Fig. 44_ Identifying Input Gear in planetary carrier.pdf
    38.4 KB · Views: 11
  • Fig. 45_ View Of Planetary Carrier trust washer.pdf
    43.1 KB · Views: 11
  • Fig. 46_ Removing Bearing In Input gear.pdf
    35.9 KB · Views: 11
  • Fig. 47_ View Of Input Gear Bearing & inner retaining ring.pdf
    34.6 KB · Views: 11
  • Fig. 48_ Removing Front Output shaft bearing inner retaining ring.pdf
    64.2 KB · Views: 10
  • Fig. 49_ Locating Front Output shaft.pdf
    52 KB · Views: 9
  • Fig. 50_ Identifying Front Output shaft seal.pdf
    66.2 KB · Views: 12
  • Fig. 51_ Removing Outer Retaining ring for the front output shaft bearing.pdf
    34.5 KB · Views: 9
  • Fig. 52_ View Of Front Output Saft bearing.pdf
    31.8 KB · Views: 10
  • Fig. 53_ Removing Cup Plug.pdf
    21.6 KB · Views: 8
  • Fig. 54_ Removing The Bearing Using J 23907 & J 26941.pdf
    73.9 KB · Views: 14
  • Fig. 55_ Locating Shift Detent lever shaft.pdf
    39.7 KB · Views: 15
  • Fig. 56_ Identifying Control Lever shaft support and seal.pdf
    51.2 KB · Views: 10
  • Fig. 57_ Identifying Inspection areas on front case.pdf
    67.8 KB · Views: 10
  • Fig. 58_ View Of Rear Case Half inspection areas.pdf
    49.4 KB · Views: 11
  • Fig. 59_ Oil Pump.pdf
    35.2 KB · Views: 11
  • Fig. 60_ Locating Inspection Areas on rear output shaft.pdf
    54.6 KB · Views: 12
  • Fig. 61_ View Of High_Low Planetary carrier inspection areas.pdf
    66.9 KB · Views: 11
  • Fig. 62_ Drive Chain and Sprockets.pdf
    58.4 KB · Views: 11
part4
 

Attachments

  • Fig. 63_ Inspecting Drive Sprocet sleeve journal surface.pdf
    60.7 KB · Views: 10
  • Fig. 64_ Front Output Shaft.pdf
    44.3 KB · Views: 12
  • Fig. 65_ Input Gear.pdf
    48.6 KB · Views: 13
  • Fig. 66_ Shift System Components.pdf
    54.3 KB · Views: 16
  • Fig. 67_ View Of High_Low Shift fork inspection areas.pdf
    30.8 KB · Views: 14
  • Fig. 68_ Identifying Inspection areas on 2_4 wheel drive mode shift fork.pdf
    47.9 KB · Views: 11
  • Fig. 69_ Locating Inspection Areas on range sleeve.pdf
    62 KB · Views: 12
  • Fig. 70_ Inspecting Control Actuator lever shaft for wear.pdf
    35.2 KB · Views: 12
  • Fig. 71_ Exploded View Of Synchonizer assembly.pdf
    58.7 KB · Views: 13
  • Fig. 72_ Installing Adapter Studs.pdf
    42.7 KB · Views: 14
  • Fig. 74_ Installing Front Output shaft bearing.pdf
    78.5 KB · Views: 11
  • Fig. 75_ Identifying Control Lever shaft support and seal.pdf
    51.2 KB · Views: 9
  • Fig. 76_ Locating Shift Detent lever shaft.pdf
    39.7 KB · Views: 9
  • Fig. 77_ View Of Input Gear Bearing & inner retaining ring.pdf
    34.6 KB · Views: 10
  • Fig. 78_ Locating Front Output shaft bearing.pdf
    36.7 KB · Views: 10
  • Fig. 79_ Installing Front Output shaft front bearing inner retaining ring.pdf
    37.1 KB · Views: 13
  • Fig. 80_ View Of Cup Plug.pdf
    20.2 KB · Views: 12
  • Fig. 81_ Installing Front Output shaft assembly.pdf
    29.7 KB · Views: 11
  • Fig. 82_ Identifying Front Output shaft front bearing outer retaining ring.pdf
    44.4 KB · Views: 9
  • Fig. 83_ View Of Planetary Carrier trust washer.pdf
    43.1 KB · Views: 10
Part5
 

Attachments

  • Fig. 84_ Installing Bearing In input gear with J8092 & J 45383.pdf
    51.3 KB · Views: 13
  • Fig. 85_ Identifying Input Gear in planetary gear.pdf
    38.4 KB · Views: 9
  • Fig. 86_ Locating Planetary Carrier front trust washer.pdf
    37 KB · Views: 9
  • Fig. 87_ View Of Planetary Carrier lock plate.pdf
    40.7 KB · Views: 12
  • Fig. 88_ Identifying Input Gear retaining ring.pdf
    40.3 KB · Views: 10
  • Fig. 89_ Locating Outer Retaining ring.pdf
    52.8 KB · Views: 9
  • Fig. 90_ Installing Input Gear bearing outer retaining ring.pdf
    49.9 KB · Views: 11
  • Fig. 91_ Identifying High_Low Shift fork on high_low range sleeve.pdf
    22.2 KB · Views: 11
  • Fig. 92_ Locating Drive Sprocket sleeve.pdf
    26.1 KB · Views: 12
  • Fig. 93_ Exploded View Of Synchrinizer assembly.pdf
    58.7 KB · Views: 12
  • Fig. 94_ View Of Synchronizer Rings on the rear output shaft.pdf
    66.7 KB · Views: 10
  • Fig. 95_ Identifying Synchronizer retaining ring.pdf
    44.5 KB · Views: 10
  • Fig. 96_ View Of 2_4 Wheel Drive mode shift fork.pdf
    32.7 KB · Views: 11
  • Fig. 97_ Installing Mode Shift fork.pdf
    35.1 KB · Views: 17
  • Fig. 98_ Identifying 2_4 Wheel syncronizer gear.pdf
    61.3 KB · Views: 9
  • Fig. 99_ Locating Drive Chain & sprockets.pdf
    37.3 KB · Views: 9
  • Fig. 100_ View Of Drive Sprocket retaining ring.pdf
    39.8 KB · Views: 10
  • Fig. 101_ Identifying Driven Sprocket retaining ring.pdf
    49.1 KB · Views: 10
  • Fig. 102_ Locating Oil Pump.pdf
    36.2 KB · Views: 12
  • Fig. 103_ View Of Oil Pump Suction pipe o-ring.pdf
    22.9 KB · Views: 10
part6
 

Attachments

  • Fig. 104_ Identifying Speed Reluctor wheel.pdf
    33.9 KB · Views: 10
  • Fig. 105_ Installing Rear Output shaft bearing.pdf
    33.2 KB · Views: 14
  • Fig. 106_ Locating Rear Output shaft bearing retaining ring.pdf
    37.2 KB · Views: 8
  • Fig. 107_ Identifying Shift Detent bolt.pdf
    23.3 KB · Views: 10
  • Fig. 108_ View Of Oil Pump Assembly.pdf
    47.6 KB · Views: 10
  • Fig. 109_ Identifying Transfercase magnet.pdf
    40.9 KB · Views: 11
  • Fig. 110_ Locating Shift Fork Spring.pdf
    59.7 KB · Views: 9
  • Fig. 111_ View Of Oil Pump Wear sleeve.pdf
    31.2 KB · Views: 10
  • Fig. 112_ Installing Locating Pins.pdf
    47.2 KB · Views: 9
  • Fig. 113_ Identifying Sealant Locations on front case.pdf
    34.2 KB · Views: 8
  • Fig. 114_ View Of Rear Case & Front case halves.pdf
    38.2 KB · Views: 11
  • Fig. 115_ Opening Rear Output Shaft beaering outer retaining ring with snap pliers.pdf
    58.1 KB · Views: 11
  • Fig. 116_ View Of Case Half Bolt or studs & Alu washers.pdf
    50.1 KB · Views: 9
  • Fig. 117_ Installing J 45380 In transfer case.pdf
    95.2 KB · Views: 13
Part7
 

Attachments

  • Fig. 118_ Installing The Rear Output shaft seal to the transfer case using j-37668-a.pdf
    29.3 KB · Views: 12
  • Fig. 119_ Installing The Front output shaft seal in the transfer cse using J-43484 & J8092.pdf
    53.3 KB · Views: 10
  • Fig. 120_ Installing Input Shaft seal in transfer case.pdf
    53.5 KB · Views: 13
  • Fig. 121_ View Of Vehicle Speed sensor o-ring seal.pdf
    75.8 KB · Views: 12
  • Fig. 122_ Identifying Vent Tube elbow.pdf
    59.6 KB · Views: 9
  • Fig. 123_ Locating Gear Indicator switch.pdf
    51.2 KB · Views: 9
  • Fig. 124_ Installing Shift Control lever retaining bolt.pdf
    42.4 KB · Views: 10
  • Fig. 125_ Identifying Access Hole plug.pdf
    69.6 KB · Views: 9
  • Fig. 126_ View Of Fill & Drain plugs.pdf
    60.3 KB · Views: 8
  • Transfer case - Overhaul - NVG 261-NP2.pdf
    1.7 MB · Views: 21
awesome. thanks.

Anyone know if the slip yoke has enough play to pull the driveshaft with the rear wheels on the ground (say, 1.5" so I can clear the pinion ears for the rear U-joint) or if I need to put this up on a lift?

Tried for about 10 minutes to get it to budge enough to pull the d-shaft but i'm thinking I need a lift.... which means I have to drive it, with a dry transfer case, about 20 miles.... which I really don't want to do.
 
On any drive shaft I've worked on there has been enough room in the slip joint.

Try prying the U joint away from the yoke with a large screwdriver, the grease may be preventing the slip joint to move.
 
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