Transfer Case: Removal

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2003 Pontiac Montana, 2003 Pontiac Aztek, 2003 Oldsmobile Silhouette, 2003 Chevrolet Venture, and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Raise the vehicle.
Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
Remove the drain plug drain the transfer case oil. See appropriate SERVICING article.
Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
Remove the transfer case brace. See REMOVAL & INSTALLATION in appropriate SERVICING article.
Remove the vent tube clamp. See Fig 1.

Fig 1: Removing Transfer Case Vent Hose Clamp
Courtesy of GENERAL MOTORS CORP.
Separate the vent tube from the vent tube bracket.
Remove the vent tube from the transfer case.
CAUTION: Removal and installation of the transfer case while the transaxle is in vehicle may cause improper positioning of the park gear thrust bearing. If the transfer case fasteners are tightened while the park gear thrust bearing is out of position, the park gear thrust bearing, transaxle, and/or the transfer case will be damaged.
Remove the transfer case with the transaxle. Refer to appropriate REMOVAL & INSTALLATION article as follows:
- See REMOVAL & INSTALLATION - AZTEK & RENDEZVOUS article in AUTOMATIC TRANSMISSIONS.
- See REMOVAL & INSTALLATION - MONTANA, SILHOUETTE & VENTURE article in AUTOMATIC TRANSMISSIONS.
Install the transaxle to appropriate transaxle support fixture.
Remove and discard the left output shaft retaining ring. See Fig 2.
Rotate the transaxle 90 degrees so that the transaxle side cover is facing down. See Fig 3.
Rotate the transaxle 90 degrees.
Remove the transfer case side brace bolts (1-5), and the transfer case side brace. See Fig 4.
Remove the transfer case bolts (1-5). See Fig 5.

Fig 2: Locating Output Shaft Snap Ring
Courtesy of GENERAL MOTORS CORP.

Fig 3: Locating Transfer Case Lower Brace Bolt
Courtesy of GENERAL MOTORS CORP.

Fig 4: Locating Transfer Case Side Brace
Courtesy of GENERAL MOTORS CORP.

Fig 5: Locating Transfer Case-To-Transaxle Bolts
Courtesy of GENERAL MOTORS CORP.

WARNING: This component weighs approximately 60 pounds. Personal injury may result if you lift the component improperly.

CAUTION: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.
Remove the transfer case with the output shaft from the transaxle. See Fig 6.
Install the transfer case assembly to the Holding Fixture (J-44755). See Fig 7.
Install the retaining bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
Attach the Slide Hammer Adapter (J-6125-1B) to the Slide Hammer (J-44467). See Fig 8.

Fig 6: Removing & Installing Transfer Case Assembly
Courtesy of GENERAL MOTORS CORP.

Fig 7: Installing Transfer Case Holding Fixture
Courtesy of GENERAL MOTORS CORP.

Fig 8: Removing Output Shaft
Courtesy of GENERAL MOTORS CORP.
Install the slide hammer into the snap ring groove on the output shaft and tighten securely.
Use the slide hammer adapter and the slide hammer to remove the output shaft.
Remove the output shaft from the transfer case.
Remove the transfer case seal from the transfer case. See Fig 9.
Remove the oil dam from the transaxle. See Fig 10.
If you are replacing the transfer case, remove the transfer case lower brace bolts and the lower brace. See Fig 11.

Fig 9: Removing & Installing Case Extension Seal

Courtesy of GENERAL MOTORS CORP.

Fig 10: Removing & Installing Oil Dam

Courtesy of GENERAL MOTORS CORP.

Fig 11: Locating Transfer Case Lower Brace

Courtesy of GENERAL MOTORS CORP.