Tools Required

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Pontiac Aztek, 2003 Oldsmobile Silhouette, 2003 Chevrolet Venture, and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

J 2619-01 Slide Hammer
J 5590 Crankshaft Sprocket Installer
J 22912-O1 Split Plate Bearing Puller
J 44380 Bearing Race Remover
J 44737 Bearing Remover
J 44754 Bearing Remover
J 44755 Holding Fixture

Fig 1: Removing Drain Plug From Extension Housing

G01365527

Courtesy of GENERAL MOTORS CORP.

Remove the drain plug (1) from the extension housing. Allow the gear oil to drain.
Remove the drain plug (1) from the case-left. Allow the transmission oil to drain.

Fig 2: Removing Drain Plug From Case Left
Courtesy of GENERAL MOTORS CORP.
Install the transfer case assembly (1) onto the J 44755 (3). Position the carrier onto the post of the fixture.

Fig 3: Installing Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
Install the retaining bolts (2).
Tighten

Tighten the bolts to 50 N.m (37 lb ft).
Remove the hose and clamp assembly (1), vent hose with bracket (2), and bolt (3).

Fig 4: Removing Hose And Clamp Assembly, Vent Hose With Bracket And Bolt
Courtesy of GENERAL MOTORS CORP.
Remove the speed sensor (1).

Fig 5: Removing Speed Sensor
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Remove the O-ring seal from the sensor, if required. The O-ring seal may be reused if not cut or damaged.
Remove the extension housing assembly (1), bolts (3), and shim (2). Mark or tag the shim for assembly.

Fig 6: Removing Extension Housing Assembly, Bolts And Shim
Courtesy of GENERAL MOTORS CORP.
If reusing the driven shaft bearings, measure in both directions, the rotating torque of the driveshaft and record the value for assembly.

Fig 7: Measuring Rotating Torque Of Driveshaft
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Install the extension housing assembly (3) and the M8 x 1.25 bolts (1) to the J 44755 (2).

Fig 8: Installing Extension Housing Assembly And Bolts
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the bolts to 25 N.m (18 lb ft).
Remove the nut (1).

Fig 9: Removing Nut
Courtesy of GENERAL MOTORS CORP.
Remove the extension housing assembly and bolts from J 44755.
Position the extension housing assembly into a press.

Fig 10: Positioning Extension Housing Assembly Into A Press
Courtesy of GENERAL MOTORS CORP.
Remove the flange (1), spacer (5), and shaft (9) from the housing (6). Discard the spacer (5).

Fig 11: Removing Flange, Spacer, And Shaft From Housing And Discard Spacer
Courtesy of GENERAL MOTORS CORP.
Remove the oil seal (2) and bearing (3).
Use the J 44380 (2) and the J 2619-01 (1) in order to remove the bearing races from the housing (3), if required.

Fig 12: Removing Bearing Race Using SST
Courtesy of GENERAL MOTORS CORP.
Install J 22912-O1 (1) or equivalent onto the shaft.

Fig 13: Installing J 22912-O1 On Shaft
Courtesy of GENERAL MOTORS CORP.
Position the shaft into a press.
Remove the bearing from the shaft.
Remove the bolts (1 and 5), housing (2), shim (3), and O-ring seal (4) from the case-left. Mark or tag the shim for assembly.

Fig 14: Removing Bolts, Housing, Shim, And O-Ring Seal
Courtesy of GENERAL MOTORS CORP.
Remove the bolts (1) from the case.

Fig 15: Removing Bolts
Courtesy of GENERAL MOTORS CORP.

Important:

When separating the case halves, avoid damage to the sealing surfaces. Do not insert a screwdriver or prying tool between the case sealing surfaces.

Fig 16: Separating Case-Right From Case-Left
Courtesy of GENERAL MOTORS CORP.
Rotate the J 44755 90 degrees.
Separate the case-right (2) from the case-left (1).
Remove the idler gear (1) from the case-right.

Fig 17: Removing Idler Gear
Courtesy of GENERAL MOTORS CORP.
Note the installed position of the idler gear. The side of the gear with the longer flange area (1) is to be installed to the case-right.

Fig 18: Identifying Flange Area Of Idler Gear
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Install the J 22912-O1 (1) onto the gear (2).

Fig 19: Installing J 22912-O1 Onto Gear
Courtesy of GENERAL MOTORS CORP.
Position the gear into a press.
Remove the bearings (1 and 3) from the gear (2).

Fig 20: Removing Bearings From Gear
Courtesy of GENERAL MOTORS CORP.
Install the case-left (2) onto the J 44755 (1). Align the notched area of the tool with the flat areas of the driveshaft.

Fig 21: Installing Case-Left Onto J 44755
Courtesy of GENERAL MOTORS CORP.
Remove the nut (1) from the driveshaft.

Fig 22: Removing Nut From Driveshaft
Courtesy of GENERAL MOTORS CORP.
Position the case-left into a press.

Fig 23: Positioning Case-Left Into A Press
Courtesy of GENERAL MOTORS CORP.
Remove the gear (8), bearing (7), shim (5), and shaft (1) from the case-left. Mark or tag the shim for assembly.

Fig 24: Removing Gear, Bearing, Shim, And Shaft
Courtesy of GENERAL MOTORS CORP.
Use the J 44380 (2) and the J 2619-01 (1) in order to remove the bearing races from the case-left (3).

Fig 25: Removing Bearing Races Using SST
Courtesy of GENERAL MOTORS CORP.
Remove the oil seals (4) from the case-left.

Fig 26: Removing Oil Seals From Case-Left
Courtesy of GENERAL MOTORS CORP.
Install the J 22912-O1 (1) or equivalent onto the shaft.

Fig 27: Installing J 22912-O1 Onto Shaft
Courtesy of GENERAL MOTORS CORP.
Position the shaft into a press.
Remove the bearing from the shaft.
Install J 44380 (2) into the case-left idler gear bearing race.

Fig 28: Installing J 44380 Into Case-Left Idler Gear Bearing Race
Courtesy of GENERAL MOTORS CORP.
Install J 2619-01 (1) to J 44380 (2).
Remove the idler gear bearing race (1) from the case-left.

Fig 29: Removing Idler Gear Bearing Race
Courtesy of GENERAL MOTORS CORP.
Install the case-right (1) onto the J 44755 (2). Position the carrier onto the post of the fixture.

Fig 30: Installing Case-Right Onto J 44755
Courtesy of GENERAL MOTORS CORP.
Remove the oil seal (1) from the case-right.

Fig 31: Removing Oil Seal From Case-Right
Courtesy of GENERAL MOTORS CORP.
Remove the nut (1) from the carrier.

Fig 32: Removing Nut From Carrier
Courtesy of GENERAL MOTORS CORP.
Position the case-right into a press.

Fig 33: Installing J 5590 To Differential Carrier
Courtesy of GENERAL MOTORS CORP.
Install the J 5590 (1) to the differential carrier.
Remove the bearing (2), shim (6) and differential carrier (8) from the case-right (4). Mark or tag the shim for assembly.

Fig 34: Removing Bearing, Shim And Differential Carrier
Courtesy of GENERAL MOTORS CORP.
Use the J 44380 (2) and the J 2619-01 (1) in order to remove the bearing races from the case-right (3), if required.

Fig 35: Removing Bearing Races Using SST
Courtesy of GENERAL MOTORS CORP.
Install the J 44754 (1) over the differential carrier bearing.

Fig 36: Installing J 44754 Over Differential Carrier Bearing
Courtesy of GENERAL MOTORS CORP.
Install the J 22912-O1 (3) over the J 44754 (2). Tighten until snug.

Fig 37: Installing J 22912-O1 Over J 44754
Courtesy of GENERAL MOTORS CORP.
Position the carrier and J 5590 (1) into a press in order to remove the bearing.
Install the J 44380 (2) into the case-right idler gear bearing race.

Fig 38: Installing J 2619-01 To J 44380
Courtesy of GENERAL MOTORS CORP.
Install J 2619-01 (1) to J 44380 (2).
Remove the bearing race (1) and shim (2). Mark or tag the shim for assembly.

Fig 39: Removing Bearing Race And Shim
Courtesy of GENERAL MOTORS CORP.
Install the J 44737 (2) into the driveshaft bearing. Tighten the tool until snug.

Fig 40: Installing J 2619-01 To J 44737
Courtesy of GENERAL MOTORS CORP.
Install the J 2619-01 (1) to the J 44737 (2).
Remove the bearing (3) from the case-right.

Fig 41: Removing Bearing From Case-Right
Courtesy of GENERAL MOTORS CORP.
Remove the roll pin (2) and shaft (1) from the differential carrier, if required.

Fig 42: Removing Roll Pin And Shaft
Courtesy of GENERAL MOTORS CORP.
Remove the side gears (2), pinion gears (3), and washers (1 and 4) from the carrier, if required.

Fig 43: Removing Side Gears, Pinion Gears, And Washers
Courtesy of GENERAL MOTORS CORP.
Remove the ring (10) from the carrier, if required.

Fig 44: Removing Pin, Gear And Washers
Courtesy of GENERAL MOTORS CORP.
Remove the pin (9), gear (3) and washers (1, 2, 7, and 8) from the carrier, if required.
Remove the needle bearings (4 and 6) and washer (5) from the gear (3), if required.

J 44755 Holding Fixture