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Transfer Case Removal

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CAUTION: ATF circulates between transaxle and transfer case. In situations where transaxle related failures circulate debris into transfer case, transfer case must be disassembled, cleaned, and inspected for damage.
  1. Remove output shaft snap ring. See Fig 1. Rotate transaxle 90 degrees. Remove transfer case lower brace bolt. See Fig 2. Rotate transaxle 90 degrees.
  2. Remove transfer case side brace. See Fig 3. Remove transfer case-to-transaxle bolts. See Fig 4.
    3. CAUTION: During transfer case/output shaft removal, DO NOT use excessive force or damage to bushings may occur.
  3. Remove transfer case assembly from transaxle. See Fig 5. Remove transfer case lower brace. See Fig 6. Remove case extension seal from transfer case. See Fig 7.
  4. Position transaxle with case side cover facing down. Remove oil dam from transaxle. See Fig 8. Install transfer case assembly onto Holding Fixture (J 44755). See Fig 9.
  5. Using Slide Hammer (J-6125-1B) and Adapter (J-44467), remove output shaft. See Fig 10. Remove final drive sun gear. See Fig 11.
  6. Remove sun gear thrust washer from transaxle. See Fig 12. Remove parking gear and thrust bearing. See Fig 13. Remove final drive sun gear shaft. See Fig 14.
Fig 1: Locating Output Shaft Snap Ring
G00057586Courtesy of GENERAL MOTORS CORP.
Fig 2: Locating Transfer Case Lower Brace Bolt
G00057599Courtesy of GENERAL MOTORS CORP.
Fig 3: Locating Transfer Case Side Brace
G00057587Courtesy of GENERAL MOTORS CORP.
Fig 4: Locating Transfer Case-To-Transaxle Bolts
G00057588Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Transfer Case Assembly
G00057589Courtesy of GENERAL MOTORS CORP.
Fig 6: Locating Transfer Case Lower Brace
G00057590Courtesy of GENERAL MOTORS CORP.
Fig 7: Removing & Installing Case Extension Seal (AWD)
G00057591Courtesy of GENERAL MOTORS CORP.
Fig 8: Removing & Installing Oil Dam (AWD)
G00057592Courtesy of GENERAL MOTORS CORP.
Fig 9: Installing Transfer Case Holding Fixture & Base
G00057593Courtesy of GENERAL MOTORS CORP.
Fig 10: Removing Output Shaft (AWD)
G00057594Courtesy of GENERAL MOTORS CORP.
Fig 11: Removing & Installing Final Drive Sun Gear (AWD)
G00057595Courtesy of GENERAL MOTORS CORP.
Fig 12: Removing & Installing Sun Gear Thrust Washer (AWD)
G00057596Courtesy of GENERAL MOTORS CORP.
Fig 13: Removing & Installing Parking Gear & Bearing (AWD)
G00057597Courtesy of GENERAL MOTORS CORP.
Fig 14: Removing & Installing Final Drive Sun Gear Shaft (AWD)
G00057598Courtesy of GENERAL MOTORS CORP.
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