Extension Case Removal. Pontiac Sun Runner - 4WD (Canada) 1998

For 1990-2009 cars

### Removal Procedure

1. Remove the gearshift control lever from the gearshift lever case. Refer to Gearshift Control Lever Removal .
2. Remove the four bolts from the fan shroud at the radiator.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Place a drain pan or suitable container underneath the transmission.
5. Remove the transmission oil level/filler plug (3) from the transmission.
6. Remove the transmission drain plug (1) from the transmission and drain the transmission oil.
7. Place index marks on the propeller shaft pinion flange yoke and the differential pinion flange in order to ensure the correct installation.
8. Remove the following items from the vehicle:

• | The four bolts

• | The four nuts

• | The rear propeller shaft

9. Remove the speedometer cable (3) from the speedometer driven gear case.

Remove the following items from the extension case.

• | The bolt (2).

• | The ground wire (1).

• | The speedometer driven gear case.

10. Remove the Three Way Catalytic Converter (TWC) and the muffler/tail pipe assembly from the vehicle.
11. Remove the drain pan from underneath the vehicle.
12. Support the transmission with a suitable hydraulic jack.
13. Remove the two bolts (2) from the rear transmission mount.
14. Remove the four bolts and the rear transmission crossmember from the vehicle.
15. Remove the one bolt and the rear transmission mount (2) from the extension case (1).
16. Place a wood block between the distributor gear housing and the bulkhead (2) in order to prevent the distributor and the other components from being damaged when the transmission is lowered.
17. Lower the transmission slowly until the engine contacts its support point on the wood block.
18. Remove one clamp and breather hose from the gearshift lever case.
19. Remove the ten bolts and the gearshift lever case (1) from the extension case (2).
20. Remove the twelve bolts (2) and the extension case (1) from the transmission.
21. Remove the following items from the extension case:

• | The two select return spring bolts (1).

• | The two select return springs (2).

• | The two select guide pins (3).

22. Clean the extension case-to-extension case mating surfaces.
23. Clean the gearshift lever case-to-extension case mating surfaces.
24. Inspect the extension case for cracks or porosity. Replace the extension case if cracks or porosity are present.