Retired mechanic here, I sure love your attention to detail, from marking the drive shafts to using loctite on the bolts. I have worked with mechanics who show less care than this 🤙
Years ago there was a garage owner in town who treated his workers like dirt. They got back at him by placing counterweights on the driveshaft of his car. It shook and vibrated like crazy!
@@terrywarner8657 I'm guilty of that trick. I just use a big zip tie and something relatively heavy like a couple of 7/16 nuts. Vibrate like hell. No permanent damage. And easily removed.
If he had "attention to detail" he would have: (1) Degreased and powerwashed the entire underside of the trans and transfer case prior to removal. (2) He would have soldered the electrical connections instead of doing a chincey crimp job. (3) He would have replaced the old crusty U-joints when he had the driveshaft out. (4) He would have replaced the halfshaft support bearing while he had the drive shaft out. (5) He would have cleaned the speed sensor electrical connector thoroughly prior to connection to the main harness. (6) He would have applied grease to the driveshaft splined union prior to reassembly. (7) He would have used black trim screws on the shifter boot and more professionally secured it to the floor to seal out water and dirt. (8) He would have painted the new transfer case after cleaning it prior to install. (9) He would have replaced the trans and transfer case input/output seals while they were easily accessible. (10) He would have painted the exposed metal hole he cut into the floorpan. (11) He would have gone ahead and drained and replaced the front and rear differential fluid while he was doing this job to ensure they are good to go as well. Also check the front CV joint and boots. And lastly (12) He would have documented carefully on a small notebook pad exactly what he did electrically in terms of the splicing and wiring changes and kept that notepad in his glovebox forever afterwards (to help solve electrical gremlins later). If he had done all those things, THEN you could say he had "attention to detail."
Just came across this today. I'm a licensed technician. Have lots of experience with these AWD systems. I have also done countless transfer case upgrades exactly like you did. I just wanted to say your step by step instructions are laid out perfectly and very easy to follow. Granted, I have lots of experience with these. I feel the average guy could easily perform this job over the weekend just following your steps. Very good, thoughtful, laid out instructions. Very easy to follow. Very good job putting this video together. Well done sir.
So correct. I was in the same boat. No plans on building a 4x4 mini van, but I was intrigued. Hypnotic voice maybe, Im just a gearhead and cant help myself more then likely what it was !!!!
same here. I am an offroad guy (jeep) and build my own rigs, but this is interesting and one off stuff. kinda makes me want to get a Safari and build it lol. great video and I am subscribing to channel.
From a former ARMY Diesel tech who had all passion for wrench turning absolutely obliterated during their enlistment... This tickled something deep inside me. I watch a lot of project videos and this has been by far the most informative and easy to watch/understand.
At this point the build has far exceeded what I'd be personally willing to do. However, I CAN'T STOP WATCHING!!! Super fun video. I can't wait to see what's next.
I worked for GM Canada during the height of the AWD van years, to this day there are few AWD systems that are as robust as the Astro/Safari vans were in the early years nor had the ground clearance they had or the capacity or strength in powertrains , Gm dropped the ball as you said when they went cheap and electronic , the change up to the 4WD case is a sweet change over and not hard to do, that is easier than doing a water pump and alternator on one of these for sure, in 1994 GM had a H.O. 4.3 V6 that was 210 HP only 2 yrs though because they did not meet emission standards , it was a very notable difference in driving with this motor and with snow tires on the AWD Astro/Safari they would push snow bumper deep easily, you could own and run these easily for 300k with regular maintenance great video good choice of vehicle 👍
Hi Bob, I have an 04 AWD Astro Van with a bad transmission. I've never attempted a transmission swap but have some wrenching skills and the will to save money. I want to do the 4x4 transfer case swap and a lift at the same time. Do you have any general words of the wise or recommendations for me? Should I swap the axles too? I'm a rock climber looking to do back roads and creeks in the High Sierras in order to get to my climbs at Shuteye Ridge. Much appreciated! Thanks!
Had a 95 Astro that I ordered with I think was Detroit Tru Trac Diffs and in the snow that thing was unstoppable, wish I’d have kept it, was a great Van the Wife mostly used it !
I grew up around lots of safaris and astros that friends and family owned. My parents had a 87 astro. I've always wanted to see a build like this happen. Thank you for vlogging the process!
When ever you need to change the oil in the diff or the transfer case, make sure that you undo the fill bolt then the drain. (To make sure that you can fill it back up of course!)
that makes no sense, whether or not the bolt is tough to get out you can't drive on bad fluid. so if you empty it then realize you can't get the fill bolt out, you just need to GET THE FILL BOLT OUT. there's no way around it.
@@krebgurfson5732 I disagree, makes sense to me (though you have a point too). If you need to spend a day getting the fill bot out, might as well do it before you take away your ability to drive to a shop by removing the fluid.
Thanks for a great video, I've always said 4x4 van is what I'd have if I had one family car. Now if Astros had those folding down seats they would be everything I need, a family hauler, that you could take camping, and load up with work supplies.
In the late 80's I had a great side gig changing the AMC Eagle over to a manual hand shift T case. We developed a shift lever assembly that eliminated the vacuum shift assembly, and it sold like wildfire. The first one we made is still on SX4 in my garage. GREAT JOB on that van Brother!
This is crazy, when I first started doing bike repairs I was confuesed with all the sizes, I know a lot of them now and have gotten the tools to measure I need ,but a car, THAT IS SO COMPLEX
This sent me into a rabbit hole researching transfer case types. I noticed this case has 5 bolts. My Jeep XJ has 6. The curiosity was in whether the internals or shafts would swap. If I went this route I'd want a 242, 2wd, 4hi, 4low, N and 4 Full Time. Basically a mechanical awd option, so in rain and light patches of snow, you can just leave it in 4F and not worry about binding. Ended up at D&E In The Garage, which answers a lot of questions. This is the fun stuff finding out what works with what. :-D
I don't even own a car. If I did, I'd barely mess with it, I'm honestly afraid of messing up a car, it took me years to dare to wrench on my bikes. Still excitedly watched the whole thing as if I needed to learn the process lol! And that's what you call quality video-making. When it engages you even if you have no real reason to be engaged.
As a side note of why I don't mess with mechanics... I bled the brakes on my MTB yesterday, a job which I've done at least a dozen times. Got distracted, kept turning, stripped the bolt on the bleed port. Need to buy a new rear brake! go me! ... idiot
Excellent attention to detail !! You make all us ‘shade tree’ mechanics proud of your work ! I have a 2000 AWD astro - and I love it ‘almost’ more than my 2500 gmc 4x4 !!! Lol !! Keep up the great videos !!
This project is the reason I follow the channel; you do a better job of documenting your work than some of the actual vehicle specific channels I follow. Very good work!
Dude!!! I don’t even care about Astro’s, but watching you work on the ground and film everything!!!!! --MAD PROPS!!! And your edit is super dope too!!! 👍👍👍👍👍
I’ve watched this and all the other Scruffy vids many times over the last month as I recently bought a van. My ‘service AWD’ dash light came on in my 2000 Safari yesterday and the first thought that went through my head was “well, might be time to add a 4x4 transfer case to my to-do list”, hahaha. Thank you for the quality videos, they have been a huge help. My poor van was neglected for years by the former owner and I’m busting my ass to get it back to road trip-worthy status.
I'm so tempted to go to the 233 case but the early borg Warner transfer case in the first gen vans is just AMAZING in the snow. Ridiculously better than other awd rigs. The viscous is wicked, I wish they'd continued this style. The jeep 249's with the viscous is great too, but people tend to fry the viscous... The 242 with a center differential is.... meh but better than 2wd in the snow.
I had an Old Astro Van once, it was a great van to drive. I started having some problems with it which I was squaring away slowly until some scumbags stole it... To this day when I see an Astro Van it brings back good memories... Enjoyed your video....👍
I will be removing my NVG136 transfer case today. This video is exactly what I needed! I'm not doing the NP233C swap.....I'm replacing, bearings, seals, case saver, shift actuator, bushing, etc,. Why? I live in Colorado and this vehicle performs very well in the snow as is! Thanks for the clear and concise instructions!
Thanks. I was a mechanic for decades and hands were injured. They easily hurt. Docs were saying it is in my head and I can’t keep working… fools. I can’t regardless if I want to. I would like to save this video link that shows a search on the surface of what we need as a mechanic, hand wise. I used garden rubber pads 100% of the time when getting up and down and knees are still good. I wore cheepo gloves and fingers get use to touch through them. I hope this helps. Pat
I just completed the swap and used this video as complete reference. Thank you for being so thorough! The main stuff that hung me up were the rear bolts that hold the drive shaft in. They were rusted on and I stripped them pretty quickly. It turned into a multi day project because of that, I ended up drilling holes into them and using bolt extracting bits to remove along with penetrating oil and a torch. So I'd say for anyone going to do this project, its not a bad idea to buy an extra set of those bolts in case you end up in the same situation as me. I also recommend getting a new rear output drive shaft seal incase you get a transfer case with a torn one. Keep up the great work, Shredist! yewww!
Mr. The Shredist, I am glad you recorded the process of swapping out Tcases. What helps is knowing that you can use a different vehicles t. case for this install. In the realm of Tcases, my wifes' and my '89 suburban ('Scottsdale' base trim level) has a New Process NP241 t. case and it is a 'passenger side' drop (drops to the right side of the vehicle, not the left/drivers' side of the 'Superban'. Emphasis on the 'pur' portion of that made up name. Anyway, wife and I call the suburban 'Scotty'. Lacking all originality. The trim level is the name. I'm looking up GMC Safari's/Chevy Astros and the possibility of the 4wd (not part time AWD) seems like a better choice over the RWD vans. I know that the first gen Astros/Safaris had the optional 5 speed manual from BW (Borg Warner), but was not an option in the second gen. Being able to tow 5,500 lbs with one of these vans has to be a real nice option as well. If I could afford to and if it could fit......, a cummins 2.8L I4 diesel engine swap is not a bad idea. We'll see. Kudos to you on the project. Keep the vids coming!!
The Astro/Safari AWD system works great when it is working. The number one cause of failure, tied with the encoder motor failing, is the wrong fluid, or dirty fluid that's never changed, just like the oil that was drained from this transfer case. The wrong fluid in the NP136 is like the wrong fluid in any clutch and plate limited slip rear differential, it can make the clutchpack slip and fail to engage, or stick, and fail to disengage depending on what incorrect fluid is used. This swap is a huge upgrade, but the stock system actually works really well when the transfer case fluid is maintained. I have 235/85R16 tires on my Astro and this is on my list of pending upgrades. Great vid though.
If you're ever out in the sticks working on a broken shaft or working in your garage, grab a tie down strap of some kind and loop the long end around the shaft and then loosely attach the hooks to the frame or some other point. That way when you pop the shaft loose, it doesn't come down and bonk you.
Well done tutorial on this procedure! I'm looking at a used AWD Astrovan and figured I'd search youtube for a conversion to gain low range and your video did just that! The only suggestion I'd make is to get a driveshaft shop to make a longer rear one as you can see how much further out the yoke is from the transfer case.
Most of that went completely over my head but it’s cool to see someone who knows what they’re doing in something so complex get it right Also although I didn’t understand the terminology the narration was great as always
Dude. I don't know what the rest of your channel entails, but you picked up a subscriber based solely on this video. First off, I can't say how much I appreciate somebody doing a build video like this in a dirt driveway. As someone who's been spoiled by concrete, air tools, good lighting and proper amenities, I forget and fail to appreciate how many people do WAY MORE WORK than I will ever do, and do it in comparatively piss poor conditions. I saw a guy doing an engine swap in his mustang on the grass next to his house, under a tarp, with the engine hoist on a sheet of plywood. Far from ideal, but dude was getting it DONE. Secondly, it is rare that I watch a video like this and don't start screaming at the screen about some obviously bone-headed thing that's going on. Mechanically, and procedurally, I could find NO FAULT with what you did! NONE! I hate using open flame for my shrink tube, but only because I got spoiled (again) on heat guns. Everything you did was super logical, common sense solid wrenching. And with nothing fancy, save the common-sense luxury of the tranny jack. I only had to drop one cast iron transfer case on my sternum and then struggle to get out from under it with ribs intact to know that as heavy as they look, there could be a LOT more gravity hiding in those things than you can even imagine. I hope there's enough AWD Astro vans to go around after videos like this! Super well done and well produced. I'll be checking out that whole series.
My 2001 AWD Astro also had the NV136. When I tested it out right after purchase I found that it was not engaging and replaced the actuator/encoder motor. No go, so I returned the actuator and got myself a NP231. I got from the junk yard a Jeep Liberty shifter assembly that is cable based and after cutting a hole next to my seat have that all installed. This is definitely the best off-road mod for those vans and let you achieve good capability at low cost. My entire conversion for the parts and oil was about $225 and cost me a Saturday mostly for fabricating a bracket for the shifter. The transfer case install itself was the easy part. I also reused by VSS encoder and did not need to modify the harness for the speedo.
I have a 1996 with 200k, it had a new trans when I got it 5 years ago. Great truck but they don't get good gas mileage. I also have a 94, 2WD pickup with the same motor that gets about 10mpg more and is full size. Just my 2 cents. Great video
I work as a parts delivery guy and one of the Techs at a place I deliver too has a 4x4 swapped asto and it looks like it was made yesterday it’s really cool it’s that dark green he’s got some like center line looking rims with KO2’s on it.I never knew this was a thing until I asked him about his now I want one for sure,really cool and different you don’t see 400 a day like most off roaders!
You do an amazing job breaking down complex topics - introducing the topic, providing context and getting down to specific tasks . You would be an excellent teacher. I don't have a strong interest in the topic, but I appreciate the video just for the delivery.
Great job both on the video and the van. One thing anyone doing this may want to consider while both driveshafts are out is installing 4 new U joints as they are pretty cheap insurance in the long run.
when i was 16-19yrs old My friend and his 2 little sisters and me travelled the United States racing ABA and NBL BMX races. never left us stranded snd did us well. It went to every state over that three year period
I just finished my 4x4 conversion and lift all from journeys...I also did all shocks/struts, ball joints, control arms,thicker radiator, 29in tires, and new rims on my 05 safari I found from a church with 34K miles
this was the first video of yours that ive watched and it is so well done! the production value is really great and you have an awesome voice for commentary. also this is such a unique and cool build. ive have tons of trouble with encoder motors so i love to see cool products like this deleting them. keep up the good work man youve definitely earned a subscriber
I blame you lol ...I watched this a year+ ago and called my buddy and gave him 500 bucks and drug a 99 awd astro home now 5 grand later 😀 4x4 tcase , new used engine , axle swaps, lift and a camper build out ...it never stops but the dogs love the adventure wagon
I always enjoy watching other people work on vehicles and every time i become more and more thankful for full shop access and lifts lol (perks of the job i guess lol) van looks great 👍
Copyed this video and everything worked perfect thanks video was spot on!! Am an old guy and NEED to have the four wheel drive to WORK and not worry if?? Thanks a bunch, and by the way Journeys shift kit works perfect, no worries now!!!!!
1 minute in and I already appreciate your attention to detail, as the comments below have stated. I patiently await your videos on awd Sienna's as I dream of having a real 4wd.
Very interesting. I was not away the Borg Warner had gone away. We owned 4 Astro's over the last 25 years, 91, 95, 2000 and 2002. All performed admirably in snow. I never felt the front end was uncoupled, unlike my Avalanche with 'Auto-4wd'.
That was very informative. Awesome video. Just one small tip for you: To make a great gasket scraper that won't mar your aluminum, take a short section of 1/2 or 3/4 copper pipe, smash one end flat with a hammer and then sharpen it with a file or grinder. Sharpen as necessary.
Retired mechanic here, I sure love your attention to detail, from marking the drive shafts to using loctite on the bolts. I have worked with mechanics who show less care than this 🤙
Years ago there was a garage owner in town who treated his workers like dirt. They got back at him by placing counterweights on the driveshaft of his car. It shook and vibrated like crazy!
@@terrywarner8657 !!!
@@terrywarner8657 I'm guilty of that trick. I just use a big zip tie and something relatively heavy like a couple of 7/16 nuts. Vibrate like hell. No permanent damage. And easily removed.
@@Mike-qp8bv i mean, you're definitely damaging the bearings in both the transmission and the rear diff as well as the ujoints but some ppl suck.
If he had "attention to detail" he would have: (1) Degreased and powerwashed the entire underside of the trans and transfer case prior to removal. (2) He would have soldered the electrical connections instead of doing a chincey crimp job. (3) He would have replaced the old crusty U-joints when he had the driveshaft out. (4) He would have replaced the halfshaft support bearing while he had the drive shaft out. (5) He would have cleaned the speed sensor electrical connector thoroughly prior to connection to the main harness. (6) He would have applied grease to the driveshaft splined union prior to reassembly. (7) He would have used black trim screws on the shifter boot and more professionally secured it to the floor to seal out water and dirt. (8) He would have painted the new transfer case after cleaning it prior to install. (9) He would have replaced the trans and transfer case input/output seals while they were easily accessible. (10) He would have painted the exposed metal hole he cut into the floorpan. (11) He would have gone ahead and drained and replaced the front and rear differential fluid while he was doing this job to ensure they are good to go as well. Also check the front CV joint and boots. And lastly (12) He would have documented carefully on a small notebook pad exactly what he did electrically in terms of the splicing and wiring changes and kept that notepad in his glovebox forever afterwards (to help solve electrical gremlins later).
If he had done all those things, THEN you could say he had "attention to detail."
Just came across this today. I'm a licensed technician. Have lots of experience with these AWD systems. I have also done countless transfer case upgrades exactly like you did.
I just wanted to say your step by step instructions are laid out perfectly and very easy to follow. Granted, I have lots of experience with these. I feel the average guy could easily perform this job over the weekend just following your steps. Very good, thoughtful, laid out instructions. Very easy to follow.
Very good job putting this video together. Well done sir.
This video is SO well made I just watched it through even though I have zero intention of doing this project. Your narrative and editing is on point 🤘
So correct. I was in the same boat. No plans on building a 4x4 mini van, but I was intrigued. Hypnotic voice maybe, Im just a gearhead and cant help myself more then likely what it was !!!!
same here. I am an offroad guy (jeep) and build my own rigs, but this is interesting and one off stuff. kinda makes me want to get a Safari and build it lol. great video and I am subscribing to channel.
Same here. But i was dreaming i would
From a former ARMY Diesel tech who had all passion for wrench turning absolutely obliterated during their enlistment... This tickled something deep inside me. I watch a lot of project videos and this has been by far the most informative and easy to watch/understand.
At this point the build has far exceeded what I'd be personally willing to do. However, I CAN'T STOP WATCHING!!! Super fun video. I can't wait to see what's next.
I worked for GM Canada during the height of the AWD van years, to this day there are few AWD systems that are as robust as the Astro/Safari vans were in the early years nor had the ground clearance they had or the capacity or strength in powertrains , Gm dropped the ball as you said when they went cheap and electronic , the change up to the 4WD case is a sweet change over and not hard to do, that is easier than doing a water pump and alternator on one of these for sure, in 1994 GM had a H.O. 4.3 V6 that was 210 HP only 2 yrs though because they did not meet emission standards , it was a very notable difference in driving with this motor and with snow tires on the AWD Astro/Safari they would push snow bumper deep easily, you could own and run these easily for 300k with regular maintenance
great video good choice of vehicle 👍
Hi Bob, I have an 04 AWD Astro Van with a bad transmission. I've never attempted a transmission swap but have some wrenching skills and the will to save money. I want to do the 4x4 transfer case swap and a lift at the same time. Do you have any general words of the wise or recommendations for me? Should I swap the axles too? I'm a rock climber looking to do back roads and creeks in the High Sierras in order to get to my climbs at Shuteye Ridge. Much appreciated! Thanks!
Had a 95 Astro that I ordered with I think was Detroit Tru Trac Diffs and in the snow that thing was unstoppable, wish I’d have kept it, was a great Van the Wife mostly used it !
I've watched this 10x and still haven't been bored.
Dang, you make wrenching on the van seem so easy!
Imagine if there was a lift and proper tools available.
@@MarkSDCA If you ever get tired of riding- you have a future in wrenching! You kick ass at both.
Make sure its torqued down with some lock tight
Wow, that kit is really well thought out. Props to people who designed it!
And it's less than $300? Just got to the end. Dang!!
I grew up around lots of safaris and astros that friends and family owned. My parents had a 87 astro. I've always wanted to see a build like this happen. Thank you for vlogging the process!
You need an EZ locker in the rear axle to make your van a little more capable offroad. Definitely worth the money and very easy to install.
I just bought my van yesterday, 2000 Astro cargo awd. Same as yours.
I’m definitely doing the 4x4 swap after watching this.
Thank you and great job.
This makes me miss my 2001 Safari - she was a beast and I finally laid her to rest after 430,000km man I loved her!
Mine has 515,000 km and still going great
When ever you need to change the oil in the diff or the transfer case, make sure that you undo the fill bolt then the drain. (To make sure that you can fill it back up of course!)
that makes no sense, whether or not the bolt is tough to get out you can't drive on bad fluid. so if you empty it then realize you can't get the fill bolt out, you just need to GET THE FILL BOLT OUT. there's no way around it.
@@krebgurfson5732 I disagree, makes sense to me (though you have a point too). If you need to spend a day getting the fill bot out, might as well do it before you take away your ability to drive to a shop by removing the fluid.
Thanks for a great video, I've always said 4x4 van is what I'd have if I had one family car. Now if Astros had those folding down seats they would be everything I need, a family hauler, that you could take camping, and load up with work supplies.
Jim's icy shade tree mechanic. Now I want to sell my 32 ft camper trailer and get an astro van.
In the late 80's I had a great side gig changing the AMC Eagle over to a manual hand shift T case. We developed a shift lever assembly that eliminated the vacuum shift assembly, and it sold like wildfire. The first one we made is still on SX4 in my garage.
GREAT JOB on that van Brother!
This is crazy, when I first started doing bike repairs I was confuesed with all the sizes, I know a lot of them now and have gotten the tools to measure I need ,but a car, THAT IS SO COMPLEX
Oh yea, working on cars gives you a real appreciation for how simple bikes are
@@jonnyliechty607 for sure, I think when I get a car I will keep bringing it to the shop, I don’t even want to start in that
I work on Carburators and engines, it's really once you get a hang of it, it's easy to do.
@@tylerrusty1122 I do beleive that considering how bikes have come for me, stil looks very hard
@@BMOutdoorz That's understandable, sometimes working in bikes seems harder, just depends on what you are doing
Something so addicting about the Scruffy build. I think it's inspiring watching the mods and Scruffy coming to life. Thanks for the entertainment 👍🚐.
I love the van build series ot is my favorite car video series on youtube
This sent me into a rabbit hole researching transfer case types. I noticed this case has 5 bolts. My Jeep XJ has 6. The curiosity was in whether the internals or shafts would swap. If I went this route I'd want a 242, 2wd, 4hi, 4low, N and 4 Full Time. Basically a mechanical awd option, so in rain and light patches of snow, you can just leave it in 4F and not worry about binding. Ended up at D&E In The Garage, which answers a lot of questions. This is the fun stuff finding out what works with what. :-D
I don't even own a car. If I did, I'd barely mess with it, I'm honestly afraid of messing up a car, it took me years to dare to wrench on my bikes.
Still excitedly watched the whole thing as if I needed to learn the process lol!
And that's what you call quality video-making. When it engages you even if you have no real reason to be engaged.
As a side note of why I don't mess with mechanics... I bled the brakes on my MTB yesterday, a job which I've done at least a dozen times. Got distracted, kept turning, stripped the bolt on the bleed port. Need to buy a new rear brake! go me! ... idiot
I can’t wait to get a lift kit on my Sienna! Journey’s is doing gods work by putting new life in old cars
Excellent attention to detail !! You make all us ‘shade tree’ mechanics proud of your work ! I have a 2000 AWD astro - and I love it ‘almost’ more than my 2500 gmc 4x4 !!! Lol !! Keep up the great videos !!
I always liked how these vans look, in that era where everyone had minivans these look sporty and more substantial.
This project is the reason I follow the channel; you do a better job of documenting your work than some of the actual vehicle specific channels I follow. Very good work!
FIANLLY! Time to come back to this channel.
One of the best channels
New subscriber here. This might be as good as Project Farm.
Dude!!! I don’t even care about Astro’s, but watching you work on the ground and film everything!!!!! --MAD PROPS!!! And your edit is super dope too!!! 👍👍👍👍👍
I’ve watched this and all the other Scruffy vids many times over the last month as I recently bought a van. My ‘service AWD’ dash light came on in my 2000 Safari yesterday and the first thought that went through my head was “well, might be time to add a 4x4 transfer case to my to-do list”, hahaha. Thank you for the quality videos, they have been a huge help. My poor van was neglected for years by the former owner and I’m busting my ass to get it back to road trip-worthy status.
A super common cause for that could be a failed encoder motor, could be an easy $100 fix! These vans always seem to have had a hard life haha.
I'm so tempted to go to the 233 case but the early borg Warner transfer case in the first gen vans is just AMAZING in the snow.
Ridiculously better than other awd rigs. The viscous is wicked, I wish they'd continued this style.
The jeep 249's with the viscous is great too, but people tend to fry the viscous...
The 242 with a center differential is.... meh but better than 2wd in the snow.
I had an Old Astro Van once, it was a great van to drive. I started having some problems with it which I was squaring away slowly until some scumbags stole it... To this day when I see an Astro Van it brings back good memories... Enjoyed your video....👍
I will be removing my NVG136 transfer case today. This video is exactly what I needed! I'm not doing the NP233C swap.....I'm replacing, bearings, seals, case saver, shift actuator, bushing, etc,. Why? I live in Colorado and this vehicle performs very well in the snow as is! Thanks for the clear and concise instructions!
Thanks. I was a mechanic for decades and hands were injured. They easily hurt. Docs were saying it is in my head and I can’t keep working… fools. I can’t regardless if I want to. I would like to save this video link that shows a search on the surface of what we need as a mechanic, hand wise. I used garden rubber pads 100% of the time when getting up and down and knees are still good. I wore cheepo gloves and fingers get use to touch through them. I hope this helps. Pat
This is the first video I've watched of yours. Great editing!
These videos are excellent! Thank you!
I just completed the swap and used this video as complete reference. Thank you for being so thorough! The main stuff that hung me up were the rear bolts that hold the drive shaft in. They were rusted on and I stripped them pretty quickly. It turned into a multi day project because of that, I ended up drilling holes into them and using bolt extracting bits to remove along with penetrating oil and a torch. So I'd say for anyone going to do this project, its not a bad idea to buy an extra set of those bolts in case you end up in the same situation as me. I also recommend getting a new rear output drive shaft seal incase you get a transfer case with a torn one. Keep up the great work, Shredist! yewww!
This was absolutely killer. And $200 for a transfer case isn't bad at all
I miss my 98 GMC Safari. Best snow vehicle I've ever driven.
I dont have an ASTRO, go four wheeling or live in a van, but I did watch this while video and subscribed. Really enjoyed your vid!
Chicagoland viewer and I just can not believe how non rusted out that van is!!!
Omg how did i miss this crucial part of scruffy's journey ?? Nice to see scruffy is all in now with the 4x4 set up , awesome .....
living in Australia, we don't have these vehicles, so I'll never do this,
but enjoyed watching anyhow and wish we had these vans over here.
My 95 has the g80 rear locker in the back it works really good,
i am so excited for the rain to leave, i want to go riding
I just picked up a 2005 Astro AWD w/ 99k miles, very clean.
Mr. The Shredist, I am glad you recorded the process of swapping out Tcases. What helps is knowing that you can use a different vehicles t. case for this install. In the realm of Tcases, my wifes' and my '89 suburban ('Scottsdale' base trim level) has a New Process NP241 t. case and it is a 'passenger side' drop (drops to the right side of the vehicle, not the left/drivers' side of the 'Superban'. Emphasis on the 'pur' portion of that made up name. Anyway, wife and I call the suburban 'Scotty'. Lacking all originality. The trim level is the name.
I'm looking up GMC Safari's/Chevy Astros and the possibility of the 4wd (not part time AWD) seems like a better choice over the RWD vans. I know that the first gen Astros/Safaris had the optional 5 speed manual from BW (Borg Warner), but was not an option in the second gen. Being able to tow 5,500 lbs with one of these vans has to be a real nice option as well.
If I could afford to and if it could fit......, a cummins 2.8L I4 diesel engine swap is not a bad idea. We'll see.
Kudos to you on the project. Keep the vids coming!!
Great channel. Let’s straight axle it! And 33s or 35s!!!!
The Astro/Safari AWD system works great when it is working. The number one cause of failure, tied with the encoder motor failing, is the wrong fluid, or dirty fluid that's never changed, just like the oil that was drained from this transfer case. The wrong fluid in the NP136 is like the wrong fluid in any clutch and plate limited slip rear differential, it can make the clutchpack slip and fail to engage, or stick, and fail to disengage depending on what incorrect fluid is used. This swap is a huge upgrade, but the stock system actually works really well when the transfer case fluid is maintained. I have 235/85R16 tires on my Astro and this is on my list of pending upgrades. Great vid though.
If you're ever out in the sticks working on a broken shaft or working in your garage, grab a tie down strap of some kind and loop the long end around the shaft and then loosely attach the hooks to the frame or some other point. That way when you pop the shaft loose, it doesn't come down and bonk you.
cool man. This video took a ton more work than most will realize, kudos. Looking forward to the interior plans!
Great video. Thank you. Love my own Safari and will never sell it.
Well done tutorial on this procedure! I'm looking at a used AWD Astrovan and figured I'd search youtube for a conversion to gain low range and your video did just that! The only suggestion I'd make is to get a driveshaft shop to make a longer rear one as you can see how much further out the yoke is from the transfer case.
@2:50 we have ALL been there before, thanks for sharing as the right to laugh has been earned!
Good details without monologuing endlessly.😎✌️
Let me tell you my life story...
Most of that went completely over my head but it’s cool to see someone who knows what they’re doing in something so complex get it right
Also although I didn’t understand the terminology the narration was great as always
Dude. I don't know what the rest of your channel entails, but you picked up a subscriber based solely on this video.
First off, I can't say how much I appreciate somebody doing a build video like this in a dirt driveway. As someone who's been spoiled by concrete, air tools, good lighting and proper amenities, I forget and fail to appreciate how many people do WAY MORE WORK than I will ever do, and do it in comparatively piss poor conditions. I saw a guy doing an engine swap in his mustang on the grass next to his house, under a tarp, with the engine hoist on a sheet of plywood. Far from ideal, but dude was getting it DONE.
Secondly, it is rare that I watch a video like this and don't start screaming at the screen about some obviously bone-headed thing that's going on. Mechanically, and procedurally, I could find NO FAULT with what you did! NONE! I hate using open flame for my shrink tube, but only because I got spoiled (again) on heat guns. Everything you did was super logical, common sense solid wrenching. And with nothing fancy, save the common-sense luxury of the tranny jack. I only had to drop one cast iron transfer case on my sternum and then struggle to get out from under it with ribs intact to know that as heavy as they look, there could be a LOT more gravity hiding in those things than you can even imagine.
I hope there's enough AWD Astro vans to go around after videos like this! Super well done and well produced. I'll be checking out that whole series.
My 2001 AWD Astro also had the NV136. When I tested it out right after purchase I found that it was not engaging and replaced the actuator/encoder motor. No go, so I returned the actuator and got myself a NP231. I got from the junk yard a Jeep Liberty shifter assembly that is cable based and after cutting a hole next to my seat have that all installed. This is definitely the best off-road mod for those vans and let you achieve good capability at low cost. My entire conversion for the parts and oil was about $225 and cost me a Saturday mostly for fabricating a bracket for the shifter. The transfer case install itself was the easy part. I also reused by VSS encoder and did not need to modify the harness for the speedo.
Thiis is the BEST easiest to follow video on this.
I have a 1996 with 200k, it had a new trans when I got it 5 years ago. Great truck but they don't get good gas mileage. I also have a 94, 2WD pickup with the same motor that gets about 10mpg more and is full size. Just my 2 cents. Great video
I work as a parts delivery guy and one of the Techs at a place I deliver too has a 4x4 swapped asto and it looks like it was made yesterday it’s really cool it’s that dark green he’s got some like center line looking rims with KO2’s on it.I never knew this was a thing until I asked him about his now I want one for sure,really cool and different you don’t see 400 a day like most off roaders!
You do an amazing job breaking down complex topics - introducing the topic, providing context and getting down to specific tasks . You would be an excellent teacher. I don't have a strong interest in the topic, but I appreciate the video just for the delivery.
Great job both on the video and the van. One thing anyone doing this may want to consider while both driveshafts are out is installing 4 new U joints as they are pretty cheap insurance in the long run.
Your very good at explaining everything. Your clear and concise. Nice job.
I miss these vans and the full time awd. I still have a 98 that I use for overlanding and the awd still works.
You have a knack for narration. Excellent video and keep up the great work with Scruffy.
when i was 16-19yrs old My friend and his 2 little sisters and me travelled the United States racing ABA and NBL BMX races. never left us stranded snd did us well. It went to every state over that three year period
Man I don’t miss working on cars, good job dude
Really pleased to see these wrenching videos back. Keen to see more trail building as well as the weather warms up too
My mom had a maroon astro when i was a kid and we took thw backseat out to haul our atv around. It was pretty cool
Automotive and mountain biking, two of my favorite things.
I just finished my 4x4 conversion and lift all from journeys...I also did all shocks/struts, ball joints, control arms,thicker radiator, 29in tires, and new rims on my 05 safari I found from a church with 34K miles
BEST VIDEO OUT THERE YET I HAVE SEEN WITH THE SPECIFIC INFORMATION! HAD TO WATCH IT AGAIN!
Thanks your instructions were great, a future project in the making!
Can’t believe you did all that without even a crawler. That’s awesome! Enjoying your build.
this was the first video of yours that ive watched and it is so well done! the production value is really great and you have an awesome voice for commentary. also this is such a unique and cool build. ive have tons of trouble with encoder motors so i love to see cool products like this deleting them. keep up the good work man youve definitely earned a subscriber
Brilliant video. One of the clearest explanations of a semi-complicated process I've ever seen. Well done!
I blame you lol ...I watched this a year+ ago and called my buddy and gave him 500 bucks and drug a 99 awd astro home now 5 grand later 😀
4x4 tcase , new used engine , axle swaps, lift and a camper build out ...it never stops but the dogs love the adventure wagon
Never have I ever thought about using my motorcycle jack as a tranny jack while doing stuff on the ground. Cool swap.
Watching these kinds of videos is like getting all the fun from working on your own projects without the expense! Great stuff
always considered doing this.
So i have seen a few videos of this swap.
Your video is BY FAR the BEST and easiest to understand and follow.
I always enjoy watching other people work on vehicles and every time i become more and more thankful for full shop access and lifts lol (perks of the job i guess lol) van looks great 👍
Copyed this video and everything worked perfect thanks video was spot on!! Am an old guy and NEED to have the four wheel drive to WORK and not worry if?? Thanks a bunch, and by the way Journeys shift kit works perfect, no worries now!!!!!
good job, I can totally relate, when you dropped the oil plug from the transfer case into the pail and when you dropped the drive shaft on your head.
Luckily the driveshaft missed my head!
1 minute in and I already appreciate your attention to detail, as the comments below have stated. I patiently await your videos on awd Sienna's as I dream of having a real 4wd.
VERY well done video !
If only all diy videos were put together and explained step by step as well as this one .
Favourite van build.
Practical and entertaining.
Four Footed Scruffy! Cool project, Mr Shredist. I'm curious to see what your carpentry skills produce inside.
Very interesting. I was not away the Borg Warner had gone away. We owned 4 Astro's over the last 25 years, 91, 95, 2000 and 2002. All performed admirably in snow. I never felt the front end was uncoupled, unlike my Avalanche with 'Auto-4wd'.
the Astro van is one of the best cars of all time
first video I've come across from you and very much liked how you explained everything without a bunch of filler bs .subscribed. good work 👍
This guy is a legend
Cool smooth background music. Keeps me in a focused mode and I’m getting more from your instruction vs head banging music.
That was very informative. Awesome video.
Just one small tip for you: To make a great gasket scraper that won't mar your aluminum, take a short section of 1/2 or 3/4 copper pipe, smash one end flat with a hammer and then sharpen it with a file or grinder. Sharpen as necessary.
This is my dream build. Thanks for the informative video, easily understood.
I've been waiting for part 4. Can't wait for Part 5 and as we head into spring, hopefully it will come sooner rather than later.
I have no desire to ever own an Astro but thought your presentation was top notch. I watched all the way to the end
Good luck on your journeys!
that was a relatively simple install/upgrade. Definitely worth the effort.
Love the van build sir its a great build and I firmly believe vans are underrated.
Only commenting because I found an AWD astro panel van in a salvage yard yesterday. Still complete.