Removal Procedure

Important:  Transmission oil circulates between the transmission and the transfer case. In situations where transmission failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. Refer to Internal Components Cleaning and Inspection in Transfer Case - Steyr Unit Repair.

1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
   Fig 1: Removing Transfer Case & Seal

   Courtesy of GENERAL MOTORS CORP.
2. Remove the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
3. Remove the drain plug (1) drain the transfer case oil.
4. Remove the drain plug (1) in order to drain the transmission fluid.
5. Disconnect the vehicle speed sensor electrical connector.
6. Remove the transfer case brace. Refer to Support Brace Replacement .
   Fig 2: Removing Drain Plug

   Courtesy of GENERAL MOTORS CORP.
7. Remove the vent tube clamp (1).
8. Separate the vent tube from the vent tube bracket.
9. Remove the vent tube from the transfer case.
   NOTE: Removal and installation of the transfer case while the transmission 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, transmission, and/or the transfer case will be damaged.
10. Remove the transfer case with the transaxle. Refer to TRANSMISSION REPLACEMENT (M15) or TRANSMISSION REPLACEMENT (M76) .
11. Install the transaxle to the transmission support fixture.
    Fig 3: Removing Transfer Case & Components

    Courtesy of GENERAL MOTORS CORP.
12. Remove and discard the left output shaft retaining ring (1).
    Fig 4: Removing Left Output Shaft Retaining Ring

    Courtesy of GENERAL MOTORS CORP.
13. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
    Fig 5: Removing Transmission Side Cover & Bolts

    Courtesy of GENERAL MOTORS CORP.
14. Rotate the transaxle 90 degrees.
15. Remove the transfer case side brace bolts (1 through 5), and the transfer case side brace (6).
    Fig 6: Removing Transfer Case Side Brace & Bolts

    Courtesy of GENERAL MOTORS CORP.
16. Remove the transfer case bolts (1 through 5).
    Fig 7: Removing Transfer Case & Bolts

    Courtesy of GENERAL MOTORS CORP.
    CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
    NOTE: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.
17. Remove the transfer case (1) with the output shaft (2) from the transaxle (3).
    Fig 8: Removing Transfer Case & Output Shaft

    Courtesy of GENERAL MOTORS CORP.
18. Install the transfer case assembly to the J 44755  .
    NOTE: Refer to FASTENER NOTICE .
19. Install the retaining bolts.

    Tighten 

    Tighten the bolts to 50 N.m (37 lb ft).

    Fig 9: Installing Transfer Case Assembly & Retaining Bolts

    Courtesy of GENERAL MOTORS CORP.
20. Attach the J 6125-1B  to the J 44467  .
21. Install the J 44467  into the snap ring groove on the output shaft (510) and tighten securely.
22. Use the J 6125-1B  and the J 44467  to remove the output shaft.
23. Remove the output shaft from the transfer case. Perform the following steps.
    Fig 10: Removing Output Shaft Using J 6125-1B

    Courtesy of GENERAL MOTORS CORP.
24. Remove the transfer case seal (1) from the transfer case (2).
    Fig 11: Removing Transfer Case & Seal

    Courtesy of GENERAL MOTORS CORP.
25. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).
    Fig 12: Removing Transfer Case Lower Brace & Bolts

    Courtesy of GENERAL MOTORS CORP.