Montana, Silhouette, Venture 2000-2005

Transfer Case Removal & Installation

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  1. Raise and support the vehicle.
  2.  
  3. Remove propeller shaft.
    NOTE
    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.

  4.  
  5. Remove the drain plug and washer from the extension housing. Allow the gear oil to drain.
  6.  
  7. Remove the drain plug and washer from the case. Allow the transmission fluid to drain.
  8.  
  9. Disconnect the electrical connector from the speed sensor.
  10.  
  11. Remove the transfer case lower brace bolts.
  12.  
  13. Remove the transfer case lower brace.
  14.  
  15. Disconnect the clamp from the extension housing vent hose coupling.
  16.  
  17. Remove the bolt retaining the vent hose bracket to the transfer case.
  18.  
  19. Remove the vent hose coupling, vent hose, and bracket from the transfer case.
  20.  
  21. Remove the transaxle.
  22.  
  23. Remove the output shaft retaining ring.
  24.  
  25. Rotate the transaxle 90 degrees.
  26.  
  27. Remove the transfer case lower brace bolt.
  28.  
  29. Rotate the transaxle 90 degrees to the installed position.
  30.  
  31. Remove the transfer case side brace bolts. Remove the side brace.
  32.  
  33. Remove the transfer case-to-transaxle bolts.
    CAUTION
    This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

  34.  
  35. Remove the transfer case assembly from the transaxle. Note that the transaxle output shaft withdraws from the transaxle with the transfer case assembly.
  36.  
  37. Remove the output shaft.
  38.  
  39. Remove the transfer case O-ring seal from the transfer case.
  40.  

To install:


NOTE
The end play clearance between the transmission and transfer case internal components is adjusted by selection of the proper size selective washer (located behind the transmission sun gear). The transmission-to-transfer case washer selection procedure must be performed each time a transmission and/or transfer case assembly or the internal components (excluding gaskets and seals) are replaced.

  1. Perform the transmission-to-transfer case end play check.
  2.  
  3. Install the O-ring seal to the transfer case.
  4.  
  5. Rotate the transaxle so that the bottom pan is facing the floor.
  6.  
  7. Install the transfer case assembly to the transaxle.

    Click image to see an enlarged view

    Fig. Install the transfer case-to-transaxle bolts and tighten the bolts in this sequence

  8.  
  9. Install the transfer case-to-transaxle bolts and tighten the bolts in the following sequence:
    1. Tighten the transfer case-to-transaxle bolts (1) and (2).
    2.  

  10.  

First pass 35 Nm (26 ft. lbs.).

Final pass an additional 160 degrees.

  1. Tighten the transfer case-to-transaxle bolt (3).
  2.  

First pass 35 Nm (26 ft. lbs.).

Final pass an additional 70 degrees.

  1. Tighten the transfer case-to-transaxle bolts (4) and (5) to 40 Nm (30 ft. lbs.).
  2.  

  1. Install the transfer case side brace.
  2.  
  3. Install the transfer case side brace-to-transaxle bolts. Hand tighten bolts.

    Click image to see an enlarged view

    Fig. Transfer case side brace-to-transaxle bolts torque sequence

  4.  
  5. Tighten the bolts in the following sequence (1, 2, 3, 4, 5) to 47 Nm (35 ft. lbs.).
  6.  
  7. Rotate the transaxle 90 degrees.
  8.  
  9. Install the transfer case lower brace-to-transaxle bolt. Tighten transfer case lower brace bolt to 47 Nm (35 ft. lbs.).
  10.  
  11. Install the output shaft to the transmission.
  12.  
  13. Install a new output shaft retaining ring.
  14.  
  15. Install the transaxle.
  16.  
  17. Install the vent hose and coupling to the extension housing.
  18.  
  19. Connect the clamp to the vent hose coupling.
  20.  
  21. Install the vent hose bracket and bolt/stud to the transfer case. Tighten the bolt/stud to 10 Nm (106 inch lbs.).
  22.  
  23. Connect the electrical connector to the speed sensor.
  24.  
  25. Install propeller shaft.
  26.  
  27. Install the transfer case lower brace.
  28.  
  29. Install the transfer case lower brace bolts. Tighten the brace bolts to 47 Nm (35 ft. lbs.).
  30.  
  31. Install the lubricant drain plug and gasket to the case. Tighten the drain plug to 32 Nm (24 ft. lbs.).
  32.  
  33. Inspect the transmission fluid level.
  34.  
  35. Install the lubricant drain plug and gasket to the extension housing. Tighten the drain plug to 32 Nm (24 ft. lbs.).
  36.  
  37. Remove the extension housing fill plug and gasket.
  38.  
  39. Fill the extension housing with synthetic gear oil GM  P/N United States 12378514 GM P/N Canada 88901045.
  40.  
  41. Install the fill plug and gasket to the extension housing. Tighten the extension housing fill plug to 32 Nm (24 ft. lbs.).
  42.  
  43. Lower the vehicle.
  44.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    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.

  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the transfer case oil.
  8.  
  9. Drain the transmission fluid.
  10.  
  11. Remove or disconnect the following:
    WARNING
    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.



    Propeller shaft
     
    Vehicle speed sensor electrical connector
     
    Vent tube from the transfer case
     



    Transfer case with the transaxle
     

  12.  
  13. Install the transaxle to the transmission support fixture.
  14.  
  15. Remove and discard the left output shaft retaining ring.
  16.  
  17. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
  18.  
  19. Remove the transfer case side brace bolts, and the transfer case side brace.
  20.  
  21. Remove the transfer case bolts.
    WARNING
    During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.

  22.  
  23. Remove the transfer case with the output shaft from the transaxle.

    Click image to see an enlarged view

    Fig. Showing the J 44755 transfer case holding fixture

  24.  
  25. Install the transfer case assembly to the J 44755, or equivalent.
  26.  
  27. Install the retaining bolts and tighten the bolts to 37 ft. lbs. (50 Nm).

    Click image to see an enlarged view

    Fig. Indicating the J 44467 output shaft remover

  28.  
  29. Attach the J 6125-1B, or equivalent slide hammer to the J 44467.
  30.  
  31. Install the J 44467 into the snap ring groove on the output shaft (510) and tighten securely.
  32.  
  33. Use the J 6125-1B and the J 44467 to remove the output shaft.
  34.  
  35. Remove the output shaft from the transfer case.
  36.  
  37. Remove the transfer case seal from the transfer case.

    Click image to see an enlarged view

    Fig. Removing the oil dam

  38.  
  39. Remove the oil dam (901) from the transaxle.
  40.  

To install:


NOTE
If you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed.

  1. Install or connect the following:
    WARNING
    The oil dam must be installed with the notch aligned to the oil passage in the transaxle case.



    New transfer case seal
     



    Oil dam to the transaxle
     

  2.  
  3. Rotate the transaxle 90 degrees, then position the transfer case to the transaxle.

    Click image to see an enlarged view

    Fig. Showing the transfer case bolt torque sequence

  4.  
  5. Install and tighten the transfer case bolts in the following sequence:

    Transfer case bolts (1) and (2) and tighten the bolts to 26 ft. lbs. (35 Nm), then rotate the bolts 160 degrees
     
    Transfer case bolt (3) and tighten the bolt to 26 ft. lbs. (35 Nm), then rotate the bolts 70 degrees
     
    Transfer case bolts (4) and (5) and tighten the bolts to 30 ft. lbs. (40Nm)
     

  6.  
  7. Install the transfer case side brace .

    Click image to see an enlarged view

    Fig. Showing the transfer case side bolts torque sequence

  8.  
  9. Install and tighten the remaining transfer case bolts in the following sequence:

    Tighten the transfer case side brace bolts in the order shown. Tighten transfer case side brace bolts to 24 ft. lbs. (32 Nm)
     
    Transfer case lower brace to transaxle bolt and tighten the bolt to 42 ft. lbs. (56 Nm)
     
    Transfer case lower brace to transfer case bolts and tighten the bolts to 24 ft. lbs. (32 Nm)
     

  10.  
  11. Install or connect the following:

    Output shaft to the transmission
     
    New output shaft retaining ring
     
    Transaxle with the transfer case
     
    Vent hose and the clamp to the transfer case
     
    Vehicle speed sensor electrical connector
     
    Propeller shaft
     

  12.  
  13. Fill the transfer case with the specified synthetic gear oil.
  14.  
  15. Install the transfer case lower brace.
  16.  
  17. Lower the vehicle.
  18.  
  19. Inspect and adjust the transmission fluid level.
  20.  
  21. Connect the negative battery cable.
  22.  

 
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