Transfer Case - Overhaul - Steyr Buick Rendezvous I

Fastener Tightening Specifications

Fastener Tightening Specifications

General Specifications

General Specifications

Extension Housing Shim Calculation Table - Procedure A

Extension Housing Shim Calculation Table - Procedure B

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 9

Scheme 10

Transfer Case Disassemble

Tools Required

1. J 2619-01 Slide Hammer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
2. J 5590 Crankshaft Sprocket Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
3. J 22912-01 Split Plate Bearing Puller. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
4. J 44380 Bearing Race Remover. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
5. J 44737 Bearing Remover. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
6. J 44754 Bearing Remover. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
7. J 44755 Holding Fixture. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .

1. Remove the drain plug (1) from the extension housing. Allow the gear oil to drain.
2. Remove the drain plug (1) from the left case. Allow the transmission oil to drain.
3. Install the transfer case assembly (1) onto the J 44755 (3). Position the carrier onto the post of the fixture.
4. Install the retaining bolts (2). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Remove the hose and clamp assembly (1), vent hose with bracket (2), and bolt (3).
6. Remove the speed sensor (1).
7. Remove the O-ring seal from the sensor, if required. The O-ring seal may be reused if not cut or damaged.
8. Remove the extension housing assembly (1), bolts (3), and shim (2). Mark or tag the shim for assembly.
9. If reusing the drivenshaft bearings, measure in both directions, the rotating torque of the drivenshaft and record the value for assembly.
10. Install the extension housing assembly (3) and the M8 x 1.25 bolts (1) to the J 44755 di (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
11. Remove the nut (1).
12. Remove the extension housing assembly and bolts from J 44755 .
13. Position the extension housing assembly into a press.
14. Remove the flange (1), spacer (5), and shaft (9) from the housing (6). Discard the spacer (5).
15. Remove the oil seal (2) and bearing (3).
16. Use the J 44380 (2) and the J 2619-01 (1) in order to remove the bearing races from the housing (3), if required.
17. Install J 22912-01 (1) or equivalent onto the shaft.
18. Position the shaft into a press.
19. Remove the bearing from the shaft.
20. Remove the bolts (1 and 5), housing (2), shim (3), and O-ring seal (4) from the left case. Mark or tag the shim for assembly.
21. Remove the bolts (1) from the case.
22. Rotate the J 44755 90 degrees.
23. Separate the right case (2) from the left case (1).
24. Remove the idler gear (1) from the right case.
25. 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 right case.
26. Install the J 22912-01 (1) onto the gear (2).
27. Position the gear into a press.
28. Remove the bearings (1 and 3) from the gear (2).
29. Install the left case (2) onto the J 44755 (1). Align the notched area of the tool with the flat areas of the driveshaft.
30. Remove the nut (1) from the driveshaft.
31. Position the left case into a press.
32. Remove the gear (2), bearing (3), shim (4), and shaft (1) from the left case. Mark or tag the shim for assembly.
33. Use the J 44380 (2) and the J 2619-01 (1) in order to remove the outer bearing race from the left case (3).
34. Remove the inner bearing race from the left case.
35. Remove the oil seals (1) from the left case.
36. Install the J 22912-01 (1) or equivalent onto the shaft.
37. Position the shaft into a press.
38. Remove the bearing from the shaft.
39. Install J 44380 (2) into the left case idler gear bearing race.
40. Install J 2619-01 (1) to J 44380 (2).
41. Remove the idler gear bearing race (1) from the left case.
42. Install the right case (1) onto the J 44755 (2). Position the carrier onto the post of the fixture.
43. Remove the oil seal (1) from the right case.
44. Remove the nut (1) from the carrier.
45. Position the right case into a press.
46. Install the J 5590 (1) to the differential carrier.
47. Remove the bearing (1), shim (3) and differential carrier (4) from the right case (2). Mark or tag the shim for assembly.
48. Use the J 44380 (2) and the J 2619-01 (1) in order to remove the bearing races from the right case (3), if required.
49. Install the J 44754 (1) over the differential carrier bearing.
50. Install the J 22912-01 (3) over the J 44754 (2). Tighten until snug.
51. Position the carrier and J 5590 (1) into a press in order to remove the bearing.
52. Install the J 44380 (2) into the right case idler gear bearing race.
53. Install J 2619-01 (1) to J 44380 (2).
54. Remove the bearing race (1) and shim (2). Mark or tag the shim for assembly.
55. Install the J 44737 (2) into the driveshaft bearing. Tighten the tool until snug.
56. Install the J 2619-01 (1) to the J 44737 (2).
57. Remove the bearing (3) from the right case.
58. Remove the roll pin (2) and shaft (1) from the differential carrier, if required.
59. Remove the side gears (2), pinion gears (3), and washers (1 and 4) from the carrier, if required.
60. Remove the ring (10) from the carrier, if required.
61. Remove the pin (9), gear (3) and washers (1, 2, 7, and 8) from the carrier, if required.
62. Remove the needle bearings (4 and 6) and washer (5) from the gear (3), if required.

Transfer Case Housings Cleaning and Inspection

1. Clean all case/housings in solvent.
2. Remove all sealant material from the sealing surfaces.
3. Inspect for the following: Damaged gasket sealing surfaces (1) Worn, scored, or loose bearing races or worn bearing race bores (2) Damaged bolt threads (3) Damaged oil seal bores (4) A loose, damaged, or restricted vent tube (5) Damaged speed sensor bore (6) Porosity Damage to the exterior of the case/housings

Gears Cleaning and Inspection

1. Inspect the idler gear (2) for wear, pitting, or discoloration by heat.
2. Inspect the drive and drivenshafts for worn or damaged gears (1).
3. Inspect the differential carrier and ring gear for the following: Worn gears (1) Damaged threads (2) Scored, pitted, or damaged bearing (3) Worn gear set or loose center pin (4) Worn or loose gears (5)
4. Inspect the gears (3) for abnormal wear.

Bearings and Shafts Cleaning and Inspection

1. Inspect the flange sealing surface (1) for wear, damaged bolt threads (2) and worn or damaged splines (3).
2. Inspect the drive and drivenshafts for the following: Worn gear teeth (1) Worn or scored driveshaft sealing surface (2) Worn or damaged splines (3) Damaged threads (4) Pitted, scored, or damaged bearings (5)
3. Inspect the differential carrier gear needle bearings (4 and 6) for wear. Inspect for a worn or scored pin (9).
4. Inspect the bearing rollers and races for the following: Pitting Scoring or grooves Excessive wear or other damage
5. Inspect the bearing rollers and races for heat discoloration. Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races. Bearings or races with a sign of heat discoloration must be replaced.
6. Inspect for a bent bearing cage.

Transfer Case Assemble

Tools Required

1. J 5590 Crankshaft Sprocket Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
2. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
3. J 36797-A Seal Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
4. J 44752 Bearing, Race, and Seal Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
5. J 44753 Bearing and Seal Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
6. J 44755 Holding Fixture. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
7. J 44757 Shim Selection Kit. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
8. J 44907 Bearing Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .
9. J 44908 Bearing Race Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr) .

Differential Carrier Assembly

1. Install the needle bearings (4 and 6) and washer (5) to the gear (3), if required.
2. Install the pin (9), gear (3), and washers (1, 2, 7, and 8) to the differential carrier, if required.
3. Install the ring (10) to the carrier, if required.
4. Install the side gears (2), pinion gears (3), and washers (1 and 4) to the carrier, if required.
5. Install the shaft (1) and roll pin (2) to the carrier, if required.
6. Determine if the drivenshaft has a plus, minus, or zero value (1) etched onto the end of the gear. If the drivenshaft has a plus, minus, or zero value etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure A.
7. Determine if the drivenshaft has a 4 digit measured value (1) etched onto the end of the gear. If the drivenshaft has a four-digit number etched onto the gear end, refer to Extension Housing Assembly and Shim Selection - Procedure B.

Extension Housing Assembly and Shim Selection - Procedure A

1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.
2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.
3. Measure the distance between the flange on the drivenshaft and the end of the pinion. Record the value as dimension B.
4. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft.
5. Install the drivenshaft (3) and NEW spacer (1) into the extension housing (2).
6. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.
7. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).
8. Lightly lubricate the splines of the drivenshaft with grease.
9. Install the flange (1) onto the shaft using a hydraulic press.
10. Install the extension housing assembly (3) and bolts (1) to the J 44755 (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
11. Install a new nut (1) onto the shaft. Tighten: Tighten the nut, with new bearings to 250 N.m (185 lb ft). Tighten the nut, with used bearings to 200 N.m (148 lb ft).
12. Remove the extension housing assembly and bolts from the J 44755 .
13. Measure in both directions, the rotating torque of the drivenshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 N.m (13 lb in). When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.
14. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.
15. Install the J 44757-3 (2) into the bore of the housing (1).
16. Install J 44757-9 (3) and bolts (2) to the housing (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 in). Record the value as dimension D.
18. Determine if the drivenshaft has a plus, minus, or zero value etched onto the end of the gear. Note that the handwritten 1 (1) and 7 (2) are similar. The 7 (2) will have a line drawn through the number. A comma is to be considered a decimal point.
19. Calculate the extension housing shim thickness. Refer to the Extension Housing Shim Calculation Table - Procedure A in «General Specifications»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr__general-specifications) .

Extension Housing Assembly and Shim Selection - Procedure B

1. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the extension housing.
2. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the extension housing.
3. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft.
4. Install the drivenshaft (3) and NEW spacer (1) into the extension housing (2).
5. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.
6. Use the J 36797-A (1) in order to install a new oil seal (2) into the extension housing (3).
7. Lightly lubricate the splines of the drivenshaft with grease.
8. Install the flange (1) onto the shaft using a hydraulic press.
9. Install the extension housing assembly (3) and bolts (1) to the J 44755 (2). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install a new nut (1) onto the shaft. Tighten: Tighten the nut, with new bearings to 250 N.m (185 lb ft). Tighten the nut, with used bearings to 200 N.m (148 lb ft).
11. Remove the extension housing assembly and bolts from the J 44755 .
12. Measure in both directions, the rotating torque of the drivenshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 N.m (13 lb in). When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.
13. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.
14. Determine the 4 digit value (1) on the end of the drivenshaft gear. A comma is to be considered a decimal point. Record the value as dimension E.
15. Install the J 44757-3 (2) into the bore of the housing (1).
16. Install J 44757-9 (3) and bolts (2) to the housing (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 in). Record the value as dimension D.
18. Calculate the extension housing shim thickness. Refer to Extension Housing Shim Calculation Table - Procedure B in «General Specifications»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-overhaul-steyr__general-specifications) .

Scheme 11

Scheme 12

1. Use the J 5590 (1) and a hydraulic press in order to install the bearings onto the idler gear.
2. Use the J 44752 (1) and a hydraulic press in order to install the bearing race into the left cover.
3. Install the idler gear (2) and bearing race (1) to the left case.
4. Inspect the gear for proper installation. The side of the gear with the long flange area (1) should be installed to the right case side.
5. Install the J 44757-1 (1) to the idler gear and race.
6. Install the right cover (1), bolts (2), and J 44757-8 (3) to the left case. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Using a feeler gage, measure the gap (1) in the J 44757-1 . The measured amount is the idler gear bearing shim thickness.
8. Disassemble the right case and tools from the left case.
9. Install the selected idler gear bearing shim (2) and bearing race (1) to the right case.
10. Use the J 44752 (1) and a hydraulic press in order to install the bearing race to the right case.
11. Install the driveshaft bearing (3) to the right case.
12. Use the J 44753 (1) and a hydraulic press in order to install the bearing to the right case.
13. Use the J 44753 (1) to install the transaxle side oil seal (2) to the left case. Install until the seal bottoms in the left case bore.
14. Use the J 44753 (1) to install the oil seal-gear oil side (2) to the left case. Install until the tool bottoms against the left case.
15. Use the J 44908 (1) and a hydraulic press in order to install the outer bearing race to the left case.
16. Use the J 44908 (1) and a hydraulic press in order to install the inner bearing race to the left case.
17. Use the J 44907 (1) and a hydraulic press in order to install the inner bearing (2) to the driveshaft.
18. Assemble the shaft (1), J 44757-7 shim (2), and bearing (3) to the left case.
19. Use the J 5590 (1) and a hydraulic press in order to install the shaft, J 44757-7 shim, race, and bearing to the left case.
20. Install the J 44757-2 (5) onto the driveshaft. Tighten until snug.
21. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), and nuts and washers (3) to the left case. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
22. Rotate the driveshaft, multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
23. Install J 8001 (3) onto the J 44757-6 . Position the tip (2) of the indicator onto the end of the J 44757-2 .
24. Tighten the nut (4) of the J 44757-2 to preload to the bearings and position the shaft at the bottom of travel. Use a second wrench to hold the J 44757-2 shaft. Observe the needle on the dial. When the needle movement stops, the shaft is at bottom of travel.
25. Zero the dial indicator.
26. Loosen and back-off the nut (4).
27. Tighten the nut (1) to preload the bearings and position the shaft at the top of travel. Use a second wrench to hold the J 44757-2 shaft.
28. Record the measured value on the dial indicator. Subtract the measured value from 6.0 mm (0.236 in) in order to determine the driveshaft shim required for proper bearing installation and preload.
29. Disassemble the shaft (1), bearing (3), and J 44757-7 shim (2) from the left case.
30. Install the proper size shim (2), shaft (1), bearing (3).
31. Lightly lubricate the splines of the driveshaft with grease.
32. Use the J 5590 (1) and a hydraulic press in order to install the bearing, proper size shim, and gear (2) onto the shaft.
33. Install the left case (2) onto the J 44755 (1). Align the notched area of the tool with the flat areas of the driveshaft.
34. Install a new nut (1) onto the driveshaft. Tighten: Tighten the nut to 505 N.m (372 lb ft).
35. Measure the rotating torque of the driveshaft. A properly assembled shaft and bearings should have a rotating torque of 1.5 N.m (13 lb in).
36. Use the J 44752 (1) and a hydraulic press in order to install the carrier bearing inner race to the right case.
37. Use the J 44752 (1) and a hydraulic press in order to install the carrier bearing outer race to the right case.
38. Use the J 44752 (1) and a hydraulic press in order to install the inner bearing to the differential carrier.
39. Install the carrier (4), J 44757-4 shim (3), and bearing (1) to the right case (2).
40. Use the J 44752 (1) and a hydraulic press in order to install the carrier, J 44757-4 shim, and bearing to the right case.
41. Install the right case (1) onto the J 44755 (2). Position the carrier onto the post of the fixture.
42. Install the J 44757-5 (5) onto the carrier. Tighten until snug.
43. Install the J 44757-6 (4), J 44757-8 (1), bolts (2), nuts and washers (3), and nuts (6) to the right case. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
44. Rotate the differential carrier multiple times in both directions to ensure the bearing rollers are seated to the bearing races.
45. Install J 8001 (3) onto the J 44757-6 . Position the tip (2) of the indicator onto the end of the J 44757-5 .
46. Tighten the nut (4) of the J 44757-5 to preload to the bearings and position the differential carrier at the bottom of travel. Use a second wrench to hold the J 44757-5 shaft. Observe the needle on the dial. When the needle movement stops, the carrier is at bottom of travel.
47. Zero the dial indicator.
48. Loosen and back-off the nut (4).
49. Tighten the nut (1) to preload the bearings and position the carrier at the top of travel. Use a second wrench to hold the J 44757-5 shaft.
50. Record the measured value on the dial indicator. Subtract the measured value from 10 mm (0.394 in) in order to determine the carrier shim required for proper bearing installation and preload.
51. Disassemble the carrier (4), bearing (1), and J 44757-4 shim (3) from the right case (2).
52. Install the proper size shim (3), carrier (4), and bearing (1) to the right case (2).
53. Use the J 44752 (1) and a hydraulic press in order to install the shaft, proper size shim, and bearing to the right case.
54. Install the nut (1) to the differential carrier. Tighten: Tighten the nut to 500 N.m (369 lb ft).
55. Measure the rotating torque of the carrier. A properly assembled carrier and bearings should have a rotating torque of 1.5 N.m (13 lb in).
56. Using a punch, stake the flange of the nut to the groove in the carrier shaft.
57. Use the J 44752 (1) in order to install the seal (2) to the right case.
58. Remove the right case (1) and carrier from the J 44755 (2).
59. Install a random size shim (3), housing (2), and bolts (1 and 4) to the left case. Tighten: Tighten the M8 bolts to 32 N.m (23 lb ft). Tighten the M10 bolts to 60 N.m (44 lb ft).
60. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the shim (2).
61. Install the housing (1), selected shim (2), and bolts (3) to the housing. Tighten: Tighten the bolts to 32 N.m (23 lb ft).
62. Install an M8 x 1.25 bolt (1) into a threaded hole in the flange.
63. Position the top of J 8001 (2) against the flat area of the bolt.
64. Install a wrench or socket onto the nut (1) of the driveshaft. Do not allow the shaft to rotate or move when measuring backlash.
65. Rotate the flange (2) left and right in order to measure the drive and drivenshafts gear backlash. Measure the backlash in multiple locations. The correct gear backlash is 0.2-0.3 mm (0.0078-0.0118 in).
66. Select and install the correct shim (4) to obtain the proper backlash. A change in shim thickness has a one-to-one ratio and change in gear backlash. A thicker shim will increase backlash. A thinner shim will decrease backlash.
67. Install a new O-ring (5) during final assembly.
68. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the sealing surfaces of the right case.
69. Install the idler gear (1) to the right case.
70. Install the idler gear into the right case. The side of the gear with the long flange area (1) should be installed to the right case.
71. Rotate the J 44755 90 degrees.
72. Install the right case (2) to the left case (1).
73. Install the bolts (1) and tighten as follows: Tighten: Tighten the M8x40 case bolt (1) to 32 N.m (24 lb ft). Tighten: Tighten the M10x60 case bolts (2) to 60 N.m (44 lb ft) Tighten: Tighten the M10x50 case bolt (3) LY7 only to 60 N.m (44 lb ft) Tighten: Tighten the M10x75 case stud bolts (4) LY7 only to 60 N.m (44 lb ft)
74. Install the speed sensor (1) and O-ring.
75. Install the hose and clamp (1), vent hose (2), and bolt (3). Tighten: Tighten the vent hose/speed sensor bolt to 30 N.m (22 lb ft).
76. Install the transmission oil drain plug (1) and gasket. Tighten: Tighten the drain plug to 32 N.m (24 lb ft).
77. Install the gear oil drain plug (1) and gasket. Tighten: Tighten the drain plug to 32 N.m (24 lb ft).
78. Perform the transfer case selective washer measurement procedure as required. Refer to «Transmission to Transfer Case End Play Check (F4WD Only)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-overhaul) in Transmission Unit Repair 4T65-E. Refer to the Installation and Fluid Fill Procedure in Transfer Case and/or Seal Replacement in Transfer Case - Steyr Service Manual.

Scheme 13

The vehicle is powered by the LA1 3400 V 6 engine, VIN E. Motion/power is transferred from the engine crankshaft/flywheel through the 4T65-E automatic transaxle. A three gear transfer case (1), mated to the right side of the transaxle assembly, transfers torque/power to the rear differential (5) via a propeller shaft assembly (3). The front-to-rear gear ratio is 1.013 to 1.

Scheme 14

The transfer case assembly consists of a four-piece aluminum housing, an input helical gear assembly, carrier (1), an idler helical gear (2), and a hypoid bevel gear set which consists of two shaft assemblies supported by tapered roller bearings (4). The design of this component changes power output from transverse to longitudinal and also positions the propeller shaft assembly near the centerline of the vehicle. The propeller shaft assembly, mated to the output flange of the transfer case, is constantly rotating and spins at a rate equal to an average of the two front wheels.

The transfer case is mated to the right side of the 4T65-E automatic transmission. Two types of lubricant are used within the transfer case: automatic transmission fluid for the three helical gear set and a unique hypoid gear oil for the bevel gears. Two oil seals, internal to the case (3) separate the two types of fluid.

Scheme 15

The propeller shaft assembly consists of a one-piece aluminum tube (2) and front and rear constant velocity type joints (1 and 3). The rear constant velocity joint (1) is a plunging type design and will plunge forward and rearward as required. Dust boots, at each joint, contain the joint lubricating grease and protect the components from dirt and debris. The propeller shaft assembly is retained to the transfer case output flange and the rear differential input flange by retaining bolts.

Scheme 16

The rear differential assembly consists of a torque tube assembly (6), three-piece differential housing, ring and pinion (4 and 5), and a differential carrier assembly (3).

The aluminum torque tube housing (6) contains an internal drive shaft (8) that is supported by roller bearings at each end. The internal drive shaft is retained to the front propeller shaft assembly by bolts and splined to the differential pinion shaft. External to the tube are a vehicle mounting bracket and a noise and vibration dampner (7).

The pinion shaft (5) is positioned in an aluminum pinion housing and is supported by tapered roller bearings. A shim between the pinion and differential housings provides the proper backlash for the ring and pinion. The ring gear (4) is retained externally to the differential carrier assembly (3) by bolts. Both the transfer case hypoid gears and the rear differential assembly use a unique type synthetic gear oil.

The differential carrier assembly (3) consists of a left and right side clutch pack drum, separate left and right axle sub shafts (1), left and right gerotor pump components (2 and 10), left and right clutch packs (9), left and right pistons, and internal valves.

The Versatrak® on-demand system operates as follows: The propeller shaft assembly, mated to the output flange of the transfer case, is constantly rotating and spins at a rate equal to an average of the two front wheels. Under normal straight-ahead non-slip driving conditions, the external (2) and internal (10) gears of the differential gerotor pumps are rotating at an equal rate of speed. Under those conditions, there is no speed differential between the pump gears, no pump pressure created, no clutch pack activation, and no torque transfer. During a front-wheel slip condition, the external gears (2) of the gerotor pumps rotate at a faster rate of speed than the rear-wheel driven internal gears (10). The gerotor pumps pull oil from the sump through the clutch pump check valve sending pressurized oil to each individual piston to activate the separate clutch packs. On-demand torque/drive is provided to each of the rear wheels as required. A valve internal to each piston housing controls maximum clutch pack pressure. A second valve within each housing is temperature compensating and controls fluid flow based on ambient temperature. The system operates in both forward and rearward vehicle directions.

In the event, a spare wheel of a smaller diameter is used on any of the four positions, the wheel rotational speed difference is detected by the wheel speed sensors of the anti-lock brake system (ABS) system. The powertrain control module (PCM) directs the clutch pump check valve to close and block oil flow to the gerotor pumps. The clutch pump check valve also monitors the sump oil for an over-temperature condition. If differential oil temperature exceeds 110°C (230°F), the valve will also close and block oil flow to the gerotor pumps. In both spare wheel usage and over-temperature conditions, a "closed" valve will alert the PCM to illuminate the control panel "AWD Disable" light.

Special Tools

Special Tools Illustration Tool Number/Description J 2619-O1 Slide Hammer J 5590 Crankshaft Sprocket Installer J 8001 Dial Indicator Set J 22912-01 Split Plate Bearing Puller J 36797-A Axle Seal Installer J 44380 Bearing Race Remover J 44737 Bearing Remover J 44752 Bearing, Race, and Seal Installer J 44753 Bearing and Seal Installer J 44754 Bearing Remover J 44755 Holding Fixture J 44757 Shim Selection Kit J 44907 Bearing Installer J 44908 Bearing Race Installer

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

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Scheme 24

Scheme 25

See also:
• Transmission to Transfer Case End Play Check (F4WD Only)
• Special Tools and Equipment
• General Specifications