Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing Extension Housing Vent Hose And Clamp

Courtesy of GENERAL MOTORS CORP.

Raise and support the vehicle. Refer to JACKING AND LIFTING in General Information.
Remove the extension housing vent hose (2) and clamp. Refer to VENT HOSE ASSEMBLY REPLACEMENT .
Remove the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT in Propeller Shaft.
Place a container under the extension housing.
Remove the lubricant drain plug (1) and gasket. Allow the oil to drain.

Fig 2: Removing Lubricant Drain Plug
Courtesy of GENERAL MOTORS CORP.
Remove the bolts (3), extension housing assembly (1), and shim (2) from the transfer case. Reference mark the shim for proper reassembly.

Fig 3: Removing Transfer Case Bolt
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the extension housing assembly (3) to the J 44755 (2) with M8 x 1.25 bolts.

Fig 4: Removing Flange Nut
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the bolts to 25 N.m (18 lb ft).
Remove the flange nut (1).
Remove the bolts and the extension housing assembly from the J 44755.

Fig 5: Removing Bolts And Extension Housing Assembly
Courtesy of GENERAL MOTORS CORP.
Position the extension housing assembly into a press.
Press the pinion shaft from the flange.
Remove and discard the extension housing seal.

Fig 6: Pressing Pinion Shaft From Flange
Courtesy of GENERAL MOTORS CORP.