Removal Procedure

Tools Required 

• J 35944-A  Transmission Oil Cooler and Line Flusher
• J 37096  Flywheel Holder

Important:  Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

Fig 1: Removing Coolant Recovery Bottle

Courtesy of GENERAL MOTORS CORP.

Important:  The transmission-to-transfer case end play check procedure must be performed each time the transmission, transfer case, or the internal components (excluding gaskets and seals) are replaced.

1. Remove the push pins from the coolant recovery bottle.
2. Position aside coolant recovery bottle.
3. Remove air cleaner assembly. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION & OVERHAUL  in Removal and Installation in Engine Performance.
4. Remove the automatic transmission range selector cable from the manual shaft.
5. Remove the automatic transmission range selector cable bracket. Refer to AUTOMATIC TRANSMISSION RANGE SELECTOR CABLE BRACKET REPLACEMENT   . 
6. Disconnect the wiring harness connectors from the transaxle.
7. Remove the wiring harness bracket from the side cover.
8. Remove the top four bell housing bolts (2, 3, 4, 5).
   Fig 2: Removing Top Four Bell Housing Bolts

   Courtesy of GENERAL MOTORS CORP.
9. Remove the prop shaft.
10. Remove the engine to transfer case brace.
11. Remove the frame.
    Fig 3: Removing Prop Shaft

    Courtesy of GENERAL MOTORS CORP.
12. Remove the filler tube bracket retaining bolt.
13. Remove the inspection cover.
14. Remove the torque converter bolts.
15. Disconnect the vehicle speed sensor.
16. Remove the right and left axle shafts into the transaxle. Refer to AXLE SHAFT  in Driveline/Axle-Front Wheel Drive Shafts.
17. Disconnect the transmission cooler lines.
18. Position the transmission jack under the transmission.
19. Remove the transfer case to engine mount bolts.
    Fig 4: Removing Transfer Case To Engine Mount Bolts

    Courtesy of GENERAL MOTORS CORP.
20. Remove the lower transaxle bolts (6) and stud (1).
21. Disconnect neutral safety switch.
22. Remove the transaxle from the vehicle.
23. Remove the transfer case from the transaxle. Refer to TRANSFER CASE in Removal and Installation - T/C in Transmission.
24. The transmission-to-transfer case end play check procedure must be performed each time the transmission, transfer case, or the internal components (excluding gaskets and seals) are replaced. Refer to TRANSAXLE-TO-TRANSFER CASE END PLAY in Removal and Installation - T/C in Transmission.
25. Use the J 35944-A  or equivalent in order to flush the following components:
    • The transaxle oil coolers
    • The hoses
    • The pipes
    Fig 5: Removing Lower Transaxle Bolts And Stud

    Courtesy of GENERAL MOTORS CORP.