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Home >> Chevrolet >> 2002 >> Venture Base, Van Cargo Extended >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Transfer Case - STEYR - Service) >> Repair Instructions >> Transfer Case Assembly Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  2. Remove propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
    Fig 1: Removing Propeller Shaft & Bolts
    G01827406Courtesy of GENERAL MOTORS CORP.

    Important:  Transmission oil circulates between the transmission assembly and the transfer case differential carrier and three helical gear set. In situations where transmission related failures circulate fiber type debris, such as clutch friction disc material into the transfer case, the helical gear portion of the transfer case must be disassembled, cleaned, and inspected for damage. In situations where transmission or transfer case related failures circulate metal type debris, such as bearing material, repair or overhaul of both components may be required.

  3. Remove the drain plug (1) and washer from the extension housing. Allow the gear oil to drain.
  4. Remove the drain plug (1) and washer from the case. Allow the transmission fluid to drain.
  5. Disconnect the electrical connector from the speed sensor.
    Fig 2: Removing Lubricant Drain Plug
    G01827407Courtesy of GENERAL MOTORS CORP.
  6. Remove the transfer case lower brace bolts.
  7. Remove the transfer case lower brace.
    Fig 3: Removing Transfer Case Lower Brace & Bolts
    G01827408Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the clamp from the extension housing vent hose coupling (1).
  9. Remove the bolt (3) retaining the vent hose bracket to the transfer case.
  10. Remove the vent hose coupling, vent hose (2), and bracket from the transfer case.
  11. Remove the transaxle. Refer to TRANSMISSION REPLACEMENT (M15) or TRANSMISSION REPLACEMENT (M76) .
    Fig 4: Removing Vent Hose, Coupling, Bolts & Extension Housing
    G01827409Courtesy of GENERAL MOTORS CORP.
  12. Remove the output shaft retaining ring (1).
    Fig 5: Removing Output Shaft Retaining Ring
    G01827410Courtesy of GENERAL MOTORS CORP.
  13. Rotate the transaxle 90 degrees.
  14. Remove the transfer case lower brace bolt (1).
    Fig 6: Removing Transfer Case Lower Brace Bolt
    G01827411Courtesy of GENERAL MOTORS CORP.
  15. Rotate the transaxle 90 degrees to the installed position.
  16. Remove the transfer case side brace bolts (1, 2, 3, 4, 5). Remove the side brace (6).
    Fig 7: Removing Transfer Case Lower Brace-To-Transaxle Bolt
    G01827412Courtesy of GENERAL MOTORS CORP.
  17. Remove the transfer case-to-transaxle bolts (1,2, 3, 4, 5).
    Fig 8: Removing Transfer Case-To-Transaxle Bolts
    G01827413Courtesy of GENERAL MOTORS CORP.
    CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
  18. Remove the transfer case assembly (1) from the transaxle (3). Note that the transaxle output shaft (2) withdraws from the transaxle with the transfer case assembly.
  19. Remove the output shaft (2). Refer to TRANSFER CASE .
    Fig 9: Removing Transfer Case Assembly, Transaxle & Output Shaft
    G01827414Courtesy of GENERAL MOTORS CORP.
  20. Remove the transfer case O-ring seal (1) from the transfer case (2).
    Fig 10: Removing Transfer Case O-Ring Seal
    G01827415Courtesy of GENERAL MOTORS CORP.
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