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Transfer case adapter gasket replacement instructions needed

Tiny
NATE.NICHOLS5640
  • MEMBER
  • 1999 CHEVROLET TAHOE
  • 5.7L
  • 6 CYL
  • 4WD
  • AUTOMATIC
  • 220,000 MILES
I am having trouble finding a step-by-step tutorial of removing the transfer case on the vehicle listed above.
Sunday, March 13th, 2022 AT 6:02 PM

28 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

I would be happy to provide the directions for removal and replacement, but I need to confirm which model transfer case you have. There are several options that were available.

If you look at the rear of the transfer case, there should be a steel label attached to it. Locate that and let me know which model you have.

I attached a pic below showing what it may look like.

Let me know what you find.

Joe

See pic below.
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Sunday, March 13th, 2022 AT 7:35 PM
Tiny
NATE.NICHOLS5640
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I really appreciate your response. I will get you that model number as soon as I get home from work today.
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Monday, March 14th, 2022 AT 1:22 AM
Tiny
NATE.NICHOLS5640
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Okay. So, I found the tag. But I have a question. If I have transmission fluid leaking where the transfer case bolts to the transfer case adapter does that mean I have a bad seal?
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Monday, March 14th, 2022 AT 11:46 AM
Tiny
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Hi,

If there is a leak, chances are it is a seal/gasket between the two components.

You have the NVG 246 transfer case manufactured by New Process (New Venture Gear). These are usually very reliable.

Regardless, I attach the directions below specific to this transfer case for the removal and replacement. Let me know if this helps or if there is anything I can do to help.

Take care,

Joe

See pics below.
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Monday, March 14th, 2022 AT 6:20 PM
Tiny
NATE.NICHOLS5640
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Okay. So, I successfully removed the transfer case. Now when I spin the shaft should I hear the slightest tinging noise inside the transfer case or is that a problem? Also, where the encoder motor mounts to the transfer case, is there an o ring or gasket there that could leak fluid?
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Tuesday, March 15th, 2022 AT 12:01 PM
Tiny
NATE.NICHOLS5640
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Man, I just want to say how relieved I am to have found this website. I had Googled and Googled and could not find a complete walk through. It took forever to find half a diagram of a transfer case. So, thanks a lot for sharing the knowledge.
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Tuesday, March 15th, 2022 AT 12:04 PM
Tiny
JACOBANDNICKOLAS
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Hi,

First, you are very welcome. Also, the ticking you hear is likely the gears turning against each other which is normal.

As far as a gasket, there should be a rubber gasket that is reusable. I attached the directions for the removal and replacement of the encoder below.

Let me know if this helps.

Take care,

Joe

See pics below.
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Tuesday, March 15th, 2022 AT 1:27 PM
Tiny
NATE.NICHOLS5640
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Very helpful. The encoder motor works fine but I’m wondering. If I replace the seal on the output shaft of transmission would that rubber gasket on the motor possibly still be leaking transmission fluid. I don’t want to put it back together to find that the encoder motor is leaking too. Also do you suggest any other service that could or should be done while I have the transfer case out?
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Wednesday, March 16th, 2022 AT 4:18 AM
Tiny
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Hi,

As long as the gasket is in good shape and properly torqued, it shouldn't leak. When it's apart, the only thing you can do is a general inspection.

If you notice anything, let me know.

Take care,

Joe
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Wednesday, March 16th, 2022 AT 3:47 PM
Tiny
NATE.NICHOLS5640
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Would that be the output shaft seal inside where the transfer case mounts to the adapter?
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Friday, March 18th, 2022 AT 4:43 AM
Tiny
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The output shaft is at the rear of the transmission. I attached a pic below. The highlighted area is the shaft, and the circled part is where the seal will be located.

Is that what you are referring to?

Let me know.

Joe

See pic below.
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Friday, March 18th, 2022 AT 6:53 PM
Tiny
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Yes, that is it, there is transmission fluid coming from around that seal. So, I need to replace that seal, correct?
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Saturday, March 19th, 2022 AT 5:06 PM
Tiny
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Yes, the seal should be replaced. When you do this, make sure it seats fully and lubricate the seal with ATF before installing the transfer case and the shaft that connects to it should be inspected as well.

Let me know if you have questions.

Take care,

Joe
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Saturday, March 19th, 2022 AT 7:54 PM
Tiny
NATE.NICHOLS5640
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Okay, now I’m working on this in my gravel driveway. Say a piece of dirt got on the shaft. What do you recommend cleaning the shaft with to ensure there is nothing in between the splines? Referring to the driveshafts as well.
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Sunday, March 20th, 2022 AT 5:47 AM
Tiny
NATE.NICHOLS5640
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Also I’m wondering how do I remove the seal?
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Sunday, March 20th, 2022 AT 8:58 AM
Tiny
NATE.NICHOLS5640
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Also I’m wondering how do I remove the seal
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Sunday, March 20th, 2022 AT 8:58 AM
Tiny
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Hi,

As far as the seal removal, they make a seal removal tool. See pic below. It's very basic.

Use something like brake cleaner that is very effective to clean parts. It evaporates really fast, so you can use it for this.

Let me know how things turn out for you.

Take care,

Joe
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Sunday, March 20th, 2022 AT 6:57 PM
Tiny
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Is the seal around that shaft the one I need to replace?
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Friday, March 25th, 2022 AT 11:48 AM
Tiny
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Hi,

I'm not seeing a seal. I believe I'm seeing a damaged O-ring. Take a look at the attached pic and let me know if that is what you are referring to.

Also, if there is a leak between the two components that are allowing fluid to enter the transfer case (transfer case overfull) there is an input seal on the transfer case side that can fail and cause that to happen.

Let me know.

Joe

See the pic and let me know if what I highlighted is what you are referring to. As far as the aforementioned post from me, the tool indicated isn't for that type of seal. I was thinking output shaft seal.
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Friday, March 25th, 2022 AT 12:58 PM
Tiny
NATE.NICHOLS5640
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I’m thinking that I just need to replace the gasket in between the transfer case and the extension housing. Because the transfer case wasn’t overfull. Transmission fluid was leaking from between the transfer case and ext. Housing but not getting past the seal on the transfer case.
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Saturday, March 26th, 2022 AT 9:00 AM

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