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Home >> Pontiac >> 2004 >> Aztek Base, FWD >> Repair and Diagnosis >> Transmission >> Transfer Case - STEYR >> Repair Instructions >> Transfer Case and/or Seal Replacement >> Removal Procedure

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 in General Information.
  2. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
    3. Fig 1: View Of Fill & Drain Plugs
    GM630583Courtesy of GENERAL MOTORS CORP.
  3. Remove the drain plug (1) drain the transfer case oil.
    4. Fig 2: Identifying Drain Plug
    GM630590Courtesy of GENERAL MOTORS CORP.
  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 (LA1)  or Support Brace Replacement (LY7) .
    7. Fig 3: View Of Transfer Case Hose/Clamp Assembly, Vent Hose, Bracket & Bolt
    GM630581Courtesy 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.
    10. 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 (LA1) or Transmission Replacement (LY7) in Automatic Transaxle - 4T65-E.
  11. Install the transaxle to the transmission support fixture. Refer to Transmission Support Fixture Assemble in Automatic Transaxle - 4T65-E Unit Repair.
    12. Fig 4: Locating Left Output Shaft Retaining Ring
    GM692584Courtesy of GENERAL MOTORS CORP.
  12. Remove and discard the left output shaft retaining ring (1).
    13. Fig 5: Identifying Transaxle Bolt
    GM692586Courtesy of GENERAL MOTORS CORP.
  13. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
    14. Fig 6: View Of Transfer Case Side Brace & Bolts
    GM692583Courtesy 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).
    16. Fig 7: Identifying Transfer Case Bolts
    GM677381Courtesy of GENERAL MOTORS CORP.
  16. Remove the transfer case bolts (1 through 5).
    17. Fig 8: View Of Transfer Case With Output Shaft & Transaxle
    GM692590Courtesy 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).
    18. Fig 9: Identifying J 44755
    GM750020Courtesy of GENERAL MOTORS CORP.
  18. Install the transfer case assembly to the J 44755  . See Special Tools and Equipment .
    19. NOTE: Refer to Fastener Notice in Cautions and Notices.
  19. Install the retaining bolts.

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

    20. Fig 10: View Of J 6125-1B & J 44467
    GM750028Courtesy of GENERAL MOTORS CORP.
  20. Attach the J 6125-1B  to the J 44467  . See Special Tools and Equipment .
  21. Install the J 44467  into the snap ring groove on the output shaft (510) and tighten securely. See Special Tools and Equipment .
  22. Use the J 6125-1B  and the. See Special Tools and Equipment .J 44467  to remove the output shaft. See Special Tools and Equipment .
  23. Remove the output shaft from the transfer case. Perform the following steps.
    24. Fig 11: Locating Transfer Case Seal
    GM692591Courtesy of GENERAL MOTORS CORP.
  24. Remove the transfer case seal (1) from the transfer case (2).
    25. Fig 12: Identifying Oil Dam
    GM630839Courtesy of GENERAL MOTORS CORP.
  25. Remove the oil dam from the transaxle.
    26. Fig 13: View Of Transfer Case Lower Brace Bolts & Brace
    GM630829Courtesy of GENERAL MOTORS CORP.
  26. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).
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