1998 - 2007 GM NP8 NP246 Transfer Case Complete Rebuild & Reassembly Part 2 (Chevy & GMC)

Рет қаралды 14,205

Күн бұрын

In this SECOND of a TWO part video series, we do a COMPLETE step by step rebuild and remanufacturing of the New Process Gear 246 (aka NP246) transfer case as used by GM starting in 1998 in EPIC detail. This NP246 shown is a first generation transfer case known as the Auto-Trak (or Auto-Trak I), or as regular production option (RPO) NP8. The NP246 transfer case is very similar to the NP236, and we will call out those differences as we go where we can. These transfer cases were built by New Process Gear for both GM and Chrysler, later changing to New Venture Gear. After the name change, it became the NV246 (or NVG246).
Link to part I: • 1998 - 2007 GM NP8 NP2...
The eBay and Amazon search links below are paid links, for which I may be compensated and earn a commission, if you choose to buy the parts and tools shown in this video thru them:
OG clutch shims - GM 12470944, GM 12470945, GM 12470946, GM 12470947, GM 12470948, GM 12470949, GM 12547610, GM 12547611, GM 12547612, GM 12547613, GM 12547614, GM 12547615, GM 12547616, and GM 12547617: ebay.us/UJ8Exc
Clutch shims USA Standard Gear - ZTNP29879, ZTNP29880, ZTNP29882, ZTNP29884, ZTNP29886, ZTNP29888: ebay.us/RCIWLx
Bearings - GM 12384993, GM 88962351: ebay.us/bUd3m1 or amzn.to/3BrCIfJ
Output shaft bushing - GM 15665313: ebay.us/bqJBli or amzn.to/3zi5o8t
Retaining rings - GM 12547623, GM 12547477, GM 12547475, GM 12470554, GM 12547637: ebay.us/uqDb4p
Chain (1998 - 2000 only - one blue link) - GM 12547662: ebay.us/GvuG3k
(2001 - 2007 only - three blue links) - GM 12474602: ebay.us/Jio3mk
Case saver - GM 89059653: ebay.us/q5lFRb or amzn.to/3oK9d18
Oil Pump, o-ring seal, filter - GM 12547630, GM 15547430, GM 15547432: ebay.us/8JwhzV
Case bolts, case elbow vent - GM 88996722, GM 12470561, GM 89059654: ebay.us/tJlOYl or amzn.to/3bnCw6Q
Encoder motor seal & bolts - GM 88891184, GM 25624810: ebay.us/A4tEnK
Access hole plug, speed sensor o-ring seals - GM 12470560, GM 19133158: ebay.us/KHYE7F or amzn.to/3Br0RmN
Seals - GM 12547638, GM 12474947, GM 12547466: ebay.us/lUF9bz or amzn.to/3Bw3rIb amzn.to/3zJeSLo amzn.to/3ONTngw
Loctite 640: ebay.us/2ekN8a or amzn.to/3vx7L67
ACDelco RTV sealant - GM 88864346 / ACDelco 10-2006: ebay.us/CLMy8B or amzn.to/3OM1QRt
ACDelco 10-4017 / GM 88900402 Auto-trak II fluid: ebay.us/tVpIJS or amzn.to/3bk7QmQ
Kent-Moore J-8092 drive handle: ebay.us/Twtzvg
Kent-Moore J-45380 bushing installer/remover: ebay.us/4faQwt
Kent-Moore J-37668-A rear output shaft seal installer: ebay.us/rmt3GV
or
Merchant Automotive 10695 rear output shaft seal installer: ebay.us/MUCIco
Kent-Moore J-43484 front output shaft seal installer (NP246 only): ebay.us/8aSp1I
or
Adapt-a-case T-M109RAC front output shaft seal installer: ebay.us/oYWLLt or amzn.to/3P3jXT9
Kent-Moore J-44636-1 front output shaft seal installer (NP236 only): ebay.us/AKoqFQ
Kent-Moore J-44636-2 front output shaft seal installer (NP236 only): ebay.us/Pc39p6
Kent-Moore J-42738 front input shaft seal installer: ebay.us/1OKA4O
or
Merchant Automotive 10325 front input shaft seal installer: ebay.us/amOrTe
Kent-Moore J-44295 clutch pack preload shim measuring tool: ebay.us/lzzc1s
Bearing driver set: ebay.us/tnbdJo or amzn.to/3PQketL
GM transfer case unit repair manual (use 1999 and later only): ebay.us/PIJTX1
And if I've saved you some $$ here, consider some coins for the coffee tip-jar! ko-fi.com/drshock
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Chapters:
0:00 - Re-assembly overview
0:25 - Updated clutch shim info
2:00 - Clutch pressure plate assembly installation
7:50 - Rear output shaft assembly installation
10:05 - Sprockets and chain installation
15:40 - Oil pump, reluctor wheel, and output bearing installation
26:50 - Case saver considerations
30:50 - Mating up the case halves
51:44 - Final assembly & seals
#drshock #np246 #obstruck #obstrucks
Disclaimer: DrShock, the alias for the human content creator for this KZfaq channel, is not responsible for any damages, injuries, losses, or liabilities associated with any repairs, upgrades, or maintenance performed on yours, or any other, vehicle whatsoever. No warranty, express or implied, is made as to the accuracy or completeness of any information provided within this channel. Viewing and using the “as-is" information of this channel is totally at your own risk. Always wear personal protection equipment and follow appropriate vehicle manufacturer service manual guidelines with original manufacturer parts only when performing any repairs, upgrades, or maintenance upon any vehicle.

Пікірлер: 48

@Defcon666 Жыл бұрын

Greatly appreciate you for sharing this detailed explanation overhaul on this np246, I'm in the final stages of wrapping mine up , I must have viewed this 50 times then skipping here and there making sure I didn't miss anything. 🍻

@davidmontez7435 Жыл бұрын

Excellent work, felt like I was in shop class

@R3tzl Жыл бұрын

Thank you for this very detailed video. It helped me a lot with my MP3023 transfer case. Some of these are similar, especially the planetary gear. For example, I didn't know how to replace the shaft seal on the input shaft without destroying it. But with your video I was finally able to do the steps in reverse order. Thank you Sir

@bmwvdozen Жыл бұрын

This is a fantastic reference video for assembling a 246. There are two measurements of the special tools that are a must for accurate reassembly that i cannot find here. first the range selector shaft bearing and seal assembly tool seems to have a boss that would recess the bearing below the surface of the mounting flange into the counterbore that the bearing on the shift motor sets into. i have measured the height of the flange on the drive socket in the shift motor and it seems to be around 2 millimeters above the surface of the shift motor. i suspect the boss on the bearing insertion tool is 2+ millimeters to provide clearance between the drive socket and the range selector shaft bearing. also the special tool that drives the front output shaft seal in place has a groove that establishes the planes that the two parts of the seal. a quick measurement of the depth of that groove would complete the video. Again this is a fantastic video for anyone assembling a 246. I was a machinist by trade and now have a machine shop in my garage just for building and rebuilding my own toys. i have built all of the special tools for this install.

@hawgdawging Жыл бұрын

Nicely done. Best video I seen on KZfaq. Thanks a lot.

@user-id3ft4jz1w Жыл бұрын

Thanks for the help!

@rvmonkey1669 Жыл бұрын

I wanted to thank you for your wonderful video content you’re so thorough it is really giving me the confidence to take on my transfer case overhaul myself. When you were putting the case on for the final time I couldn’t help notice that the updated antirattle clip was missing from the pump.

@DrShock Жыл бұрын

Thanks, that's the whole reason I take the time to share them. Your clip observation is just another example of how much these rebuilds can be very model year unique when done _by the book_ as I've shown here. This 1999 one intended for pairing with the 6.5L diesel V8 would not have all of the same parts originally, as well as several other differences, from 1998 and then later years. I did another video last week that really homes in on how these units varied from each other every single year.

@melissaolivares394 3 ай бұрын

Thank you sir very informative

@human3444 Жыл бұрын

Thanks for video.

@BigZaddy2112 2 ай бұрын

Outstanding! Also, your bushing/bearing seal driver kit, does it allow you to stack the 50mm and 48mm or whichever combination you choose? I`ll answer my own question, Yes! Read the tool description on the website LOL! THANKS!

@mmingle57 10 ай бұрын

Dr Shock I Loved your video rebuilding the np246 transfer case! I own a 05 silverado that I just replaced my encoder motor but currently now have an issue with the functionality of my transfer case 4wd hi. For some reason I believe the dorman encoder motor may have been shipped to me in a different phase other than neutral? My 4wd functions however I have cannot put my transfer case in 4hi from 2hi, indicating that the clock synchronization problem I believe now? This problem is what prompted me to see how a NV/NP246 transfer case goes together! Thank you so much for sharing your expertise regarding these transfer cases!!! I’m sure many like myself have learned something and found this process interesting!!!

@BTaylor-ue2nc 3 ай бұрын

Had the same problem with my 04 the encoder motor comes clocked wrong from the factory on certain brands. Good friend of mine that is a mechanic helped me figure that one out.

@marleneengleman5441 4 ай бұрын

Does the preload clutch pack have to measured for a shim with the clutch setup tool like the Nobel reload does?

@atlanticyak2069 Жыл бұрын

Great work have fun doing it all over again in 10 years lol

@DrShock Жыл бұрын

With OEM parts, more like 20 years. ;-)

@atlanticyak2069 Жыл бұрын

@@DrShock yeah yeah ok mr 4th Gen ya got me there. Us 5th gens would have to di it again in 10 years lol

@Jrls405racing 4 ай бұрын

Thanks this helped out a lot. If you don’t mind where do I fine the paperwork at

@DrShock 4 ай бұрын

Should be a link in the description where you might find an used service manual set.

@richardalves-cd5me Жыл бұрын

Great video!! I"m a pretty confident mechanic and this is my lively hood. One question if we don't have the $600+ measuring tool for the clutch pack shim what would be the alternative for this?

@DrShock Жыл бұрын

I'm not aware of any alternative aftermarket type tool for this one. Though some folks who have a machinist background may have fab'd their own versions on their lathe. What I suggest to most of us folks who don't have a lathe, is buy the Kent-Moore tool used on eBay (search links in the video description), and then resell it when you're done.

@user-uc5so7bf8t Жыл бұрын

👍👍👍👍👍👍👍👍

@jordanharris3749 Жыл бұрын

I just got through taking apart my 246, and the fork pivot pins have stripped the threads in the housing. Have you used a product like loctite form a thread for this application, or do you have any recommendations to fix these threads? Thanks!

@DrShock Жыл бұрын

There's significant force applied here, I would just replace the case half with one from an LKQ salvage yard donor. But if you just wanted a temporary repair, something like _Alvin Lab-metal_ would be worth a look.

@jordanharris3749 Жыл бұрын

@@DrShock i will look into finding a salvage unit to rebuild, thank you!

@jjohnson479 5 ай бұрын

Did I miss something. I didn't see how the planetary gear set go back in the case??? I thought you were going STEP-BY-STEP!! Otherwise great video.

@DrShock 5 ай бұрын

Did you check part I? kzfaq.info/get/bejne/Z5eUlruI08_Um40.html

@mark98070 Жыл бұрын

Could you tell me what position, N, 4H or 4L the transfer case is in at the end of this video with the shaft pointing up and down? I went to change my shift motor and when taking it off the shaft seemed to have sprung a bit and I could not get the replacement motor onto the shaft. Thank you.

@DrShock Жыл бұрын

This unit was disassembled with the encoder motor in the default 2H position (the normal driving mode). When reassembling you will want to return it to this, or whatever position you started in if different. I showed how you can use a wrench to manually reposition the selector shaft to line up with the encoder motor, whose position will reflect where you started. You know you have it when the encoder motor will simply slide back over the shaft (the motor and shaft are keyed to each other) with its mounting bolt holes in alignment.

@mark98070 Жыл бұрын

@@DrShock Thank you for your reply. I understand this, my truck would not shift out of 4Hi. The only way to drive it without binding was to pull the ATC fuse which would disengage the front axle. It was then that I decided to change the shift motor. When doing so I heard a noise like a spring releasing as I removed the old motor. The shaft had turned slightly and now I cannot lineup the replacement. I wonder if the transfer case is damaged internally, not allowing the shaft to properly align with shift motor. Or could I be 180 degrees out. I'll look in your video to where you are shifting the case manually. But I don't think there is a full half turn throughout the different modes. Any thoughts? Again, Thank you

@DrShock Жыл бұрын

I can't say I'm any sort of expert with these older transfer cases. I've rebuilt a few and am comfortable with that process, but not familiar with recognizing all of their various failure patterns. Typically, you should be able to manually cycle the selector lever just like the encoder motor would. So if you cannot get the selector to realign with the encoder motor, I would suspect either a problem with the encoder motor resting position itself, or the internal clutch mechanism for the selector inside the transfer case. Would have to open up the transfer case to confirm the latter. What's happening operationally as you cycle those selector shaft positions is tension on that clutch pack mechanism is changing. Functioning very similar to an automatic transmission clutch, just instead of hydraulic pressure it's mechanical thru the fork that the encoder motor is actuating via the selector shaft.

@elmarmeliksoy9029 3 ай бұрын

After rebuild transfer case my car does not change shifts, and speedomeger dont work my car is Chevy Tahoe 2000 . May be we did mistake anythink?

@DrShock 3 ай бұрын

For the speedometer check the speed sensor installation, and the correct sensor for this model is being used, and wiring integrity. Could also be that you do not have the sensor pickup aligned with the reluctor wheel inside the case. The lack of shifting is perhaps that the clutches were not properly done. Either way you're going to have to go back inside to find out. This model transfer case _must_ be filled with blue fluid, GM Autotrak-II transfer case fluid. And the clutch pack _must_ be properly shimmed using the special tools and procedure I went over in this video series, otherwise it will not shift properly at all. It's design is more similar to a transmission than a traditional transfer case.

@elmarmeliksoy9029 3 ай бұрын

@@DrShock we try speed sensor , after test drive i feel some sounds my transfer case then i see light on servics 4x4 odometer. Tomorrow we rebuild again. I am from Azerbaijan, Baku.

@jordanharris3749 Жыл бұрын

It looks like the 12547475 ring is discontinued by GM, where were you able to source one?

@DrShock Жыл бұрын

Yes I was, NOS. You may have to look aftermarket if you cannot find it from one of the discontinued GM parts vendors on eBay or Amazon.

@dellrempel3619 Жыл бұрын

Hi, how much is the three piece clutch pack measuring tool?

@DrShock Жыл бұрын

There's links in the video description where you can find the parts, and this tool, online.

@ryanmcrae3593 Жыл бұрын

I know your question is from two months ago, but I spent about $350 on eBay for the tool set. I do plan to re-sell it on eBay for a considerably lower price once I've used it. Let me know if you're interested.

@grim3per 2 ай бұрын

Where can I get the manual?

@DrShock 2 ай бұрын

Should be a search link in the videos description text.

@elmarmeliksoy9029 3 ай бұрын

How i get pdf manual? Can you share pls?

@DrShock 3 ай бұрын

There isn't a free one as GMs legal department will shut that down. You can buy it used (links in the description), or subscribe at www.acdelcotds.com for the electronic version.

@stevea6722 Жыл бұрын

The new and "improved" oil pump anti rattle/rub clip (29:07) would be better replaced by the Merchant Automotive pump plate. The improved clip is known to fail also.

@patrickhall6831 7 ай бұрын

I was thinking the same thing no matter what a whole plate that protects the whole pump rather than a singular piece on one side just seems like a no brainier to me only part of the video I where I was like umm I think I'm still going to do the plate

@shaneletson Ай бұрын

Wrong correction from 1999-2001 r the same 246 transfer case the shift motor is a different gear the 199-2001 has two plugs on that shift motor on the side thats a different gear the 2004 and i no 2005 r the same but i do t no how far they go up to b the same everyone of these 246 transfer case housing rubs a hole n the housing after that rattle clip breaks

@marleneengleman5441 4 ай бұрын

I mean non preload cultch.

@DrShock 4 ай бұрын

The non-preload clutch started around or after 2003. AFAIK both types do have to be shimmed. And while both determine which shim to use by using the J-44295 tool set, I believe there is a difference in setting up the tool used to measure this between the two designs. What I showed is the tool setup _only_ for the earlier design. I'm not familiar with the setup used on the later design though. Best advice would be to consult the service manual for your model year truck to be sure.