Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Montana, 2002 Oldsmobile Silhouette, and 2002 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.

Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
Remove the extension housing vent hose (2) and clamp. Refer to Vent Hose Assembly Replacement .
Remove the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .

Fig 1: Removing Extension Housing Vent Hose & Clamp
Courtesy of GENERAL MOTORS CORP.
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 & Gasket
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 Bolts, Extension Housing Assembly & Shim
Courtesy of GENERAL MOTORS CORP.

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

Tighten the bolts to 25 N.m (18 lb ft).

Fig 4: Installing Extension Housing Assembly, J 44755 & Bolts
Courtesy of GENERAL MOTORS CORP.
Remove the flange nut (1).
Remove the bolts and the extension housing assembly from the J 44755 .

Fig 5: Removing Flange Nut, Extension Housing Assembly & J 44755
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: Removing Extension Housing Seal
Courtesy of GENERAL MOTORS CORP.