LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 809 (Transfer Case - BW 4481-Nr3) >> Repair Instructions >> Transfer Case Assembly Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Yukon, 2003 Cadillac Escalade EXT, 2003 Cadillac Escalade ESV, and 2003 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  2. Remove the transfer case shield, if equipped. Refer to TRANSFER CASE SHIELD REPLACEMENT  .
  3. Remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT -- REAR in Propeller Shaft.
  4. Remove the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT -- FRONT in Propeller Shaft.
  5. Drain the fluid from the transfer case.
  6. Disconnect the speed sensor electrical connector (4).
    Fig 1: Disconnecting Speed Sensor Electrical Connector
    G01456430Courtesy of GENERAL MOTORS CORP.
  7. Remove the clip (3) from the transfer case bracket.
  8. Reposition the speed sensor wire.
  9. Remove the clips (5, 6) from the fuel pipe bracket.
  10. Remove the fuel pipe clip from the fuel pipe bracket  .
  11. Support the transmission with a suitable jack stand.
  12. Remove the transmission mount nuts.
    Fig 2: Removing Transmission Mount Nuts
    G01456431Courtesy of GENERAL MOTORS CORP.
  13. Remove the crossmember bolts.
  14. Remove the crossmember.
  15. Install a suitable transmission jack to the transfer case.
    Fig 3: Removing Crossmember
    G01456432Courtesy of GENERAL MOTORS CORP.
  16. Remove the transfer case adapter nuts.
  17. Remove the fuel pipe bracket from the studs.

    Important:  Pull straight back on the transfer case in order to position the transfer case so that it can be rotated parallel to the transmission.

  18. Remove the transfer case from the adapter.
  19. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
  20. Lower the transfer case.
  21. Remove the gasket from the transfer case.
  22. Remove the transfer case from the transmission jack.
    Fig 4: Removing Transfer Case From Adapter
    G01456433Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals