Transfer Case: Removal

WARNING: This page is about a different car, the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Raise the vehicle.
Remove the transmission support member. See REMOVAL & INSTALLATION - "G" SERIES article in AUTOMATIC TRANSMISSIONS.
Drain the transfer case. See LUBRICATION in SERVICING - EXPRESS & SAVANA article.
Remove the rear and front drive shafts from the transfer case. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
Remove the vent hose from the transfer case. See Fig 1 .
Disconnect the electrical connector from the speed sensor. See Fig 2 .

Fig 1: Removing/Installing Vent Hose From Transfer Case
Courtesy of GENERAL MOTORS CORP.

Fig 2: Disconnecting Electrical Connector From Speed Sensor
Courtesy of GENERAL MOTORS CORP.
Unclip the fuel lines from the fuel line bracket.
Install a suitable transmission jack to the transfer case.
Remove the nuts from the transfer case to the adapter.
NOTE: Pull straight back on the transfer case in order to position the transfer case so that the transfer case can be turned parallel to the transmission.
Remove the transfer case from the transfer case adapter. See Fig 3 .

Fig 3: Removing/Installing Transfer Case From Transfer Case Adapter
Courtesy of GENERAL MOTORS CORP.
Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
Lower the transfer case.
Remove the gasket from the transfer case.
Remove the transfer case from the transmission jack.