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Transfer Case - Steyr Buick Rendezvous I

Transfer Case 8 illustrations ~3240 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Carrier Nut (All)500 N.m369 lb ft
Case Left Drain Plug (All)32 N.m24 lb ft
Case M8 Bolts (All)32 N.m24 lb ft
Case M10 Bolts (All)60 N.m44 lb ft
Driven Shaft Rotating Torque (All)1.5 N.m13 lb in
Extension Housing Bolts (All)32 N.m24 lb ft
Extension Housing Drain Plug (All)32 N.m24 lb ft
Extension Housing Fill Plug (All)28 N.m21 lb ft
Flange Nut (All)250 N.m185 lb ft
Holding Fixture M8 Bolts (All)25 N.m18 lb ft
Output Driveshaft Housing M8 Bolts (All)32 N.m24 lb ft
Output Driveshaft Housing M10 Bolts (All)60 N.m44 lb ft
Output Driveshaft Nut (All)505 N.m372 lb ft
Speed Sensor/Vent Hose Bolt (All)30 N.m22 lb ft
Transfer Case Brace Bolts (LY7)50 N.m37 lb ft
Transfer Case Brace Nuts (LY7)50 N.m37 lb ft
Transfer Case Lower Brace to Transaxle Bolt (LA1)56 N.m42 lb ft
Transfer Case Lower Brace to Transfer Case Bolts (LA1)32 N.m24 lb ft
Transfer Case Side Brace Bolts (LA1)32 N.m24 lb ft
Transfer Case to Engine Oil Pan Brace Bolts (LA1)47 N.m35 lb ft
Transfer Case-to-Transaxle Bolts (In Sequence)
Transfer Case-to-Transaxle Bolts (1, 2) First Pass35 N.m26 lb ft
Transfer Case-to-Transaxle Bolts (1, 2) Final PassAdditional 160 Degrees
Transfer Case-to-Transaxle Bolt (3) First Pass35 N.m26 lb ft
Transfer Case-to-Transaxle Bolt (3) Final PassAdditional 70 Degrees
Transfer Case-to-Transaxle Bolts (4, 5)40 N.m30 lb ft

Fastener Tightening Specifications

Diagnostic Starting Point - Transfer Case

Begin the system diagnosis by reviewing the Transfer Case Disassembled View in Transfer Case-Steyr Unit Repair and the Transfer Case Description and Operation , and the Differential Carrier Assembly Description in Rear Drive Axle. Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Transfer Case in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

Review the system operations in order to familiarize yourself with the system functions. Refer to Transfer Case Disassembled View in Transfer Case - Steyr Unit Repair and Transfer Case Description and Operation , and Differential Carrier Assembly Description in Rear Drive Axle. All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

  1. Inspect for aftermarket devices, which could affect the operation of the vehicle. Refer to «Checking Aftermarket Accessories»(/buick/rendezvous/i-2001-2007/remont/body-electrical/#wiring-systems-diagnostic-information-and-procedures__checking-aftermarket-accessories) in Wiring Systems.
  2. Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom.
  3. Check for the correct lubricant levels and the proper viscosities.
  4. Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed, road conditions, ambient temperature, and other specifics.
  5. Compare the driving characteristics or sounds, if applicable, to a known good vehicle and make sure you are not trying to correct a normal condition.
  6. Inspect for all-wheel drive activation and operation. Refer to «All-Wheel Drive (AWD) System Functional Inspection»(/buick/rendezvous/i-2001-2007/remont/differentials-drive-axles/#rear-drive-axle) in Rear Drive Axle.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

  1. «Diagnostic Starting Point - Vibration Diagnosis and Correction»(/buick/rendezvous/i-2001-2007/remont/oem-general-information/#vibration-symptoms-diagnosis-and-correction__diagnostic-starting-point-vibration-diagnosis) in Vibration Diagnosis and Correction
  2. «Diagnostic Starting Point - Transfer Case»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__diagnostic-starting-point-transfer-case)
  3. «Diagnostic Starting Point - Rear Differential Carrier»(/buick/rendezvous/i-2001-2007/remont/differentials-drive-axles/#rear-drive-axle__diagnostic-starting-point-rear-differential) in Rear Drive Axle
  4. «All-Wheel Drive (AWD) System Functional Inspection»(/buick/rendezvous/i-2001-2007/remont/differentials-drive-axles/#rear-drive-axle) in Rear Drive Axle
  5. «Diagnostic Starting Point - Wheel Drive Shafts»(/buick/rendezvous/i-2001-2007/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts
  6. «Noisy in Drive»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__noisy-in-drive)
  7. «Noisy When Coasting»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__noisy-when-coasting)
  8. «Intermittent Noise»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__intermittent-noise)
  9. «Constant Noise»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__constant-noise)
  10. «Transfer Case Leak Diagnosis»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__transfer-case-leak-diagnosis)

Noisy in Drive

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Water or contamination within the transmission oil Water or contamination within the transmission fluid, causing excessive torque converter clutch slip rate, may create a "grind, growl, or moan" in the rear differential or torque tube under light or steady load conditions.Replace the transmission fluid and flush the transfer case of the contaminated fluid. Refer to Internal Components Cleaning and Inspection in Transfer Case - Steyr Unit Repair.
Loose propeller shaft mounting boltsTighten the bolts as required. Refer to Propeller Shaft Replacement in Propeller Shaft.
Worn propeller shaft constant velocity jointsReplace propeller shaft assembly. Refer to Propeller Shaft Replacement in Propeller Shaft.
Worn axle shaft constant velocity jointsReplace the constant velocity joints as required.
Loose rear axle torque tube bracket or a worn bracket bushingTighten the bracket bolts or replace the bracket as required.
Worn bearing in the rear differential torque tube assemblyReplace the torque tube assembly
Torque tube dampner loose or missing A "moan" or "exhaust leak" type noise at higher engine speeds, approximately 2,000-2,500 RPM, may indicate a loose or missing dampner.Tighten the dampner retaining bolt or replace the torque tube assembly as required.
Incorrect gear oil in the transfer caseReplace with gear oil GM P/N 12378514 (Canadian P/N 88901045).
Bearing noise within the transfer case A "grinding" or "roar" type noise will increase or decrease relative to the vehicle speed.Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required.
Gear set "whine" noise within the transfer case "Whine" type noises will increase or decrease relative to the vehicle speed approximately 80-97 km/h (50-60 mph).Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required. Contributing factors may include: Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Noisy in Drive

Noisy When Coasting

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Loose propeller shaft mounting boltsTighten the bolts as required. Refer to Propeller Shaft Replacement in Propeller Shaft.
Worn propeller shaft constant velocity jointsReplace the propeller shaft assembly. Refer to Propeller Shaft Replacement in Propeller Shaft.
Worn axle shaft constant velocity jointsReplace the constant velocity joints as required.
Loose rear differential torque tube bracket or a damaged bracket bushingTighten the bracket bolts or replace the bracket as required.
Worn bearing in the rear axle torque tube assemblyReplace the torque tube assembly.
Incorrect gear oil in the transfer caseReplace with gear oil GM P/N 12378514 (Canadian P/N 88901045).
Bearing noise within the transfer case A "grinding" or "roar" type noise will increase or decrease relative to the vehicle speed.Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required.
Gear set "whine" noise within the transfer case "Whine" type noises will increase or decrease relative to the vehicle speed, approximately 50-60 mph.Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required. Contributing factors may include: Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Noisy When Coasting

Intermittent Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Loose propeller shaft mounting boltsTighten the bolts as required. Refer to Propeller Shaft Replacement in Propeller Shaft.
Loose torque tube bracket or a damaged bracket bushingTighten the bracket bolts or replace the bracket as required.
Incorrect gear oilReplace with gear oil GM P/N 12378514 (Canadian P/N 88901045).

Intermittent Noise

Constant Noise

CauseCorrection
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement .
Low gear oil levelsFaulty oil seals or other type external leaks may contribute to lower than required fluid levels. Refer to Transfer Case Leak Diagnosis . Fill to proper level with gear oil GM P/N 12378514 (Canadian P/N 88901045).
Worn propeller shaft constant velocity jointsReplace the propeller shaft assembly. Refer to Propeller Shaft Replacement in Propeller Shaft.
Worn bearing in the rear differential torque tube assemblyReplace the torque tube assembly.
Bearing noise within the transfer case A "grinding" or "roar" type noise will increase or decrease relative to the vehicle speed.Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required.
Gear set "whine" noise within the transfer case A "whine" type noise will increase or decrease relative to the vehicle speed, approximately 50-60 mph.Check for the proper fluid level. Fill as required. If the noise continues, repair or replace the internal components as required. Contributing factors may include: Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Constant Noise

Transfer Case Leak Diagnosis

CauseCorrection
GM P/N 12378514 (Canadian P/N 88901045) Hypoid Gear Oil has ultraviolet dye already included within the oil. Drain and fill the unit with new oil before using the J 28428-E black light, when inspecting for leaks. Ultraviolet dye J 28431-6 is not approved for use.
Restricted or damaged ventilation tube assemblyReplace the ventilation tube as required.
Worn, scored, or missing drain and/or fill plug sealing washersInstall new sealing washers and tighten the plugs per specifications.
Leaking vehicle speed sensor or O-ring sealReplace the sensor and/or O-ring as required.
Worn or damaged driven shaft oil sealReplace the driven shaft oil seal and output flange as required.
Cut or damaged drive shaft housing O-ring sealReplace the O-ring seal as required.
Worn drive shaft oil seals Worn or damaged drive shaft oil seals may be detected by a fluid leak at the vent hole area on the bottom of the case. A red colored fluid indicates a transaxle fluid leak and a clear or brown colored fluid indicates a hypoid gear oil leak.Replace the oil seals and the drive/driven shafts as required.
Worn or damaged right side axle shaft oil sealReplace the axle shaft oil seal and axle shaft as required.
Cut or damaged transaxle assembly-to-transfer case O-ring sealsReplace the O-ring seals as required.
Cases or housings porosity or leaking seal surfacesReplace the cases and housings as required and reseal the assembly.

Transfer Case Leak Diagnosis

Removal Procedure

  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the fill plug (2) and gasket.
  3. Place a container under the drain plug (1) in order to catch the oil.
  4. Remove the drain plug and gasket. Allow the oil to drain.

Installation Procedure

  1. Install the drain plug (1) and gasket. Tighten: Tighten the drain plug to 32 N.m (24 lb ft).
  2. Fill the transfer case with synthetic gear oil GM P/N United States 12378514 Canada P/N 88901045, or equivalent. Refer to «Capacities - Approximate Fluid»(/buick/rendezvous/i-2001-2007/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) in General Information.
  3. Fill the transfer case to the bottom of the oil fill plug hole.
  4. Install the oil fill plug (2) and gasket. Tighten: Tighten the oil fill plug to 28 N.m (21 lb ft).
  5. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
  3. Disconnect the electrical connector from the speed sensor.
  4. Remove the speed sensor/vent hose bolt (3) from the transfer case.
  5. Reposition the pinion housing vent hose (2) and mounting bracket away from the speed sensor bolt boss.
  6. Remove the speed sensor (1).
  7. Remove O-ring from the speed sensor, if necessary. The O-ring may be reused if it is not cut or damaged.
  1. Install the O-ring to the speed sensor, if removed.
  2. Install the speed sensor (1) to the transfer case.
  3. Position the pinion housing vent hose (2) and mounting bracket to the speed sensor bolt boss.
  4. Install the speed sensor bolt (3) to the transfer case. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
  5. Connect the electrical connector to the speed sensor.
  6. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
  7. Lower the vehicle.

Axle Shaft Oil Seal Replacement

Tools Required

  1. J 2619-O1 Slide Hammer
  2. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  3. J 29794 Axle Shaft Remover Extension
  4. J 44752 Bearing, Race, and Seal Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
  3. Remove the right front wheel drive shaft. Refer to «Wheel Drive Shaft Replacement - Front»(/buick/rendezvous/i-2001-2007/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement-front) in Wheel Drive Shafts.
  4. Using the J 2619-O1 with the J 29794 and the J 23129 remove the axle shaft oil seal (1) from the transfer case. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  1. Lubricate the lip of the axle shaft oil seal with automatic transaxle fluid.
  2. Using the J 44752 install the axle shaft oil seal to the transfer case. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  3. Install the right front wheel drive shaft. Refer to «Wheel Drive Shaft Replacement - Front»(/buick/rendezvous/i-2001-2007/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement-front) in Wheel Drive Shafts.
  4. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/buick/rendezvous/i-2001-2007/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
  5. Lower the vehicle.
  6. Inspect the transaxle fluid level. Refer to «Transmission Fluid Checking Procedure»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-ediagnostics-troubleshooting__transmission-fluid-checking-procedure) in Automatic Transaxle - 4T65-E.
  7. Inspect for fluid leaks. Refer to «Fluid Leak Diagnosis»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-ediagnostics-troubleshooting) in Automatic Transaxle - 4T65-E and «Transfer Case Leak Diagnosis»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr__transfer-case-leak-diagnosis) .

Drive Pinion Flange/Yoke and/or Oil Seal Replacement

Tools Required

  1. J 36797-A Getrag Axle Output Shaft Seal Installer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  2. J 44755 Holding Fixture. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the extension housing vent hose (2) and clamp. Refer to «Vent Hose Assembly Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) or «Vent Hose Assembly Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  3. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/driveshaft-universal-joints/#propeller-shaft) in Propeller Shaft.
  4. Place a container under the extension housing.
  5. Remove the lubricant drain plug (1) and gasket. Allow the oil to drain.
  6. Remove the bolts (3), extension housing assembly (1), and shim (2) from the transfer case. Reference mark the shim for proper reassembly.
  7. If reusing the drivenshaft bearings, measure in both directions, the rotating torque of the drivenshaft and record the value for assembly.
  8. Install the extension housing assembly (3) to the J 44755 (2) with M8 x 1. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .25 bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  9. Remove the flange nut (1).
  10. Remove the bolts and the extension housing assembly from the J 44755 . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  11. Position the extension housing assembly into a press.
  12. Press the pinion shaft from the flange.
  13. Remove and discard the extension housing seal.
  1. Install the drive pinion (3) and NEW spacer (1) into the extension housing (2).
  2. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.
  3. Use the J 36797-A in order to install a new oil seal (2) into the extension housing. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  4. Position the flange and the extension housing assembly into a press.
  5. Lightly lubricate the splines on the driven shaft.
  6. Press the flange (1) onto the driven shaft.
  7. Install the extension housing assembly to the J 44755 (2) using M8 x 1. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .25 bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  8. Install the flange nut (1) onto the driven shaft. Tighten: Tighten the flange nut to 200 N.m (148 lb ft).
  9. Remove the extension housing assembly from the J 44755 . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  10. Measure the rotating torque of the driven shaft in both directions.
  11. When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten: A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 N.m (13 lb in).
  12. Reinstall J 44755 to tighten the flange nut as required to achieve the proper rotating torque value. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) . Do NOT loosen the flange nut to achieve the proper torque or a NEW spacer must be installed.
  13. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to both sides of the shim.
  14. Align the reference marks and install the shim (2) to the transfer case.
  15. Install the extension housing (1) and bolts (3) to the shim and transfer case. Tighten: Tighten the extension housing bolts to 32 N.m (24 lb ft).
  16. Install the extension housing drain plug (1) and gasket to the extension housing. Tighten: Tighten the plug to 32 N.m (24 lb in).
  17. Remove the extension housing fill plug (2) and gasket.
  18. Fill the extension housing with gear oil. Refer to «Transfer Case Fluid Replacement»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  19. Install the extension housing fill plug and gasket. Tighten: Tighten the plug to 28 N.m (21 lb in).
  20. Install the vent hose (2) and clamp (1). Refer to «Vent Hose Assembly Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) or «Vent Hose Assembly Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  21. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/driveshaft-universal-joints/#propeller-shaft) in Propeller Shaft.
  22. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Release the vent hose clamp (1) from the extension housing assembly.
  3. Disconnect the vent hose (2) from the retaining bracket on the transfer case assembly.
  4. Remove the vent hose from the extension housing assembly vent tube by carefully twisting the hose.
  1. Install the vent hose to the extension housing assembly vent tube.
  2. Connect the vent hose (2) to the retaining bracket on the transfer case assembly.
  3. Install the vent hose clamp (1) to the extension housing assembly.
  4. Lower the vehicle.
  1. Turn the ignition OFF.
  2. Remove the air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-36l-ly7-introduction) in Engine Controls - 3.6L (LY7).
  3. Remove the transfer case vent hose from the transmission fill tube.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  5. Remove the catalytic converter. Refer to «Catalytic Converter Replacement»(/buick/rendezvous/i-2001-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
  6. Disconnect the intermediate steering shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
  7. Position a utility stand beneath the rear center section of the frame in order to support the powertrain.
  8. Remove the frame rear bolts.
  9. Carefully lower the powertrain in order to provide access.
  10. Release the vent hose clamp and remove the vent hose from the transfer case.
  11. Remove the vent hose from the retainer.
  12. Remove the vent hose.
  1. Install the vent hose.
  2. Install the vent hose to the retainer.
  3. Install the vent hose to the transfer case.
  4. Raise the powertrain until the frame insulators contact the chassis.
  5. Install the frame rear bolts. Refer to «Frame Replacement - Front (W/AWD)»(/buick/rendezvous/i-2001-2007/remont/frames-subframes-crossmembers/#frame-and-underbody) or «Frame Replacement - Front (W/FWD)»(/buick/rendezvous/i-2001-2007/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
  6. Remove the utility stand.
  7. Connect the intermediate steering shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/ignition-switchsteering-lock/#steering-wheel-steering-column) in Steering Wheel and Column.
  8. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(/buick/rendezvous/i-2001-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
  9. Lower the vehicle.
  10. Install the transfer case vent hose to the transmission fill tube.
  11. Install the air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(/buick/rendezvous/i-2001-2007/remont/testing-diagnostics/#engine-controls-36l-ly7-introduction) in Engine Controls - 3.6L (LY7).
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the transaxle brace bolts.
  3. Remove the transaxle brace.
  1. Install the transaxle brace.
  2. Install the transaxle brace bolts. Tighten: Tighten the bolts to 47 N.m (35 lb ft).
  3. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the transaxle brace bolts (1 and 3) and nuts (2).
  3. Remove the transaxle brace.
  1. Install the transaxle brace.
  2. Install the transfer case brace bolts (1 and 3) and nuts (2). Tighten Tighten the transfer case brace bolts (1 and 3) to 50 N.m (37 lb ft). Tighten the transfer case brace nuts (2) to 50 N.m (37 lb ft).
  3. Lower the vehicle.

Transfer Case and/or Seal Replacement

Tools Required

  1. J 36660-A Torque Angle Meter. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  2. J 44467 Slide Hammer. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  3. J 6125-1B Slide Hammer Adapter. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  4. J 44755 Holding Fixture. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
IMPORTANTTransmission 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»(/buick/rendezvous/i-2001-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
  2. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/driveshaft-universal-joints/#propeller-shaft) in Propeller Shaft.
  3. Remove the drain plug (1) drain the transfer case oil.
  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)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) or «Support Brace Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  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. Remove the transfer case with the transaxle. Refer to «Transmission Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) or «Transmission Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) 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. Remove and discard the left output shaft retaining ring (1).
  13. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.
  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. Remove the transfer case bolts (1 through 5).
  17. Remove the transfer case (1) with the output shaft (2) from the transaxle (3).
  18. Install the transfer case assembly to the J 44755 . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  19. Install the retaining bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  20. Attach the J 6125-1B to the J 44467 . See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  21. Install the J 44467 into the snap ring groove on the output shaft (510) and tighten securely. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  22. Use the J 6125-1B and the. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) . J 44467 to remove the output shaft. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  23. Remove the output shaft from the transfer case. Perform the following steps.
  24. Remove the transfer case seal (1) from the transfer case (2).
  25. Remove the oil dam from the transaxle.
  26. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).
IMPORTANTIf you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed. Refer to Transmission to Transfer Case End Play Check (F4WD Only) in Automatic Transmission - 4T65-E Unit Repair.
  1. If you are replacing the transfer case, install the transfer case lower brace (906) and the lower brace bolts (903). Do not tighten the bolts.
  2. Install a new seal transfer case seal (1).
  3. Install the oil dam (901) to the transaxle.
  4. Rotate the transaxle 90 degrees.
  5. Install the transfer case to the transaxle.
  6. Install the transfer case bolts (1) and (2). Tighten: Tighten the bolts to 35 N.m (26 lb ft). Use the J 36660-A to rotate the bolts 160 degrees. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  7. Install the transfer case bolt (3). Tighten: Tighten the bolt to 35 N.m (26 lb ft). Use the J 36660-A to rotate the bolts 70 degrees. See «Special Tools and Equipment»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  8. Install the transfer case bolts (4) and (5). Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  9. Install the transfer case side brace (905).
  10. Install and tighten the transfer case side brace bolts in the order shown. Tighten: Tighten transfer case side brace bolts to 32 N.m (24 lb ft).
  11. Install the transfer case lower brace to transaxle bolt (1). Tighten: Tighten the bolt to 56 N.m (42 lb ft).
  12. Tighten the transfer case lower brace to transfer case bolts (903). Tighten: Tighten the bolts to 32 N.m (24 lb ft).
  13. Install the output shaft to the transmission. Refer to Output Shaft Assemble in Automatic Transaxle - 4T65-E Unit Repair.
  14. Install a new output shaft retaining ring (1).
  15. Install the transaxle with the transfer case. Refer to «Transmission Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) or «Transmission Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-e-introduction-service-replacement) in Automatic Transaxle - 4T65-E.
  16. Install the vent hose (2) and the clamp (1) to the transfer case.
  17. Install the vehicle speed sensor electrical connector.
  18. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(/buick/rendezvous/i-2001-2007/remont/driveshaft-universal-joints/#propeller-shaft) in Propeller Shaft.
  19. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to «Transfer Case Fluid Replacement»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  20. Install the drain plug (1) and gasket to the case. Tighten: Tighten the drain plug to 32 N.m (24 lb ft).
  21. Install the transfer case lower brace. Refer to «Support Brace Replacement (LA1)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) or «Support Brace Replacement (LY7)»(/buick/rendezvous/i-2001-2007/remont/transfer-case/#transfer-case-steyr) .
  22. Lower the vehicle.
  23. Inspect and adjust the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(/buick/rendezvous/i-2001-2007/remont/automatic-trans/#automatic-transaxle-4t65-ediagnostics-troubleshooting__transmission-fluid-checking-procedure) in Automatic Transaxle - 4T65-E.

Scheme 1

Scheme 1: Transfer Case Description and Operation
Scheme 1: Transfer Case Description and Operation

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.

Special Tools

Special Tools Illustration Tool Number/Description J 2619-01 Slide Hammer J 6125-1B Slide Hammer Adapter J 23129 Universal Seal Remover J 28428-E High-Intensity Black Light Kit J 29794 Axle Shaft Remover Extension J 36660-A Torque Angle Meter J 36797 Getrag Axle Output Shaft Seal Installer J 44467 Slide Hammer J 44752 Bearing, Race, and Seal Installer J 44755 Holding Fixture

Scheme 2

Scheme 2: Special Tools
Scheme 2: Special Tools

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

See also:
• Differential Carrier Assembly Description
• Strategy Based Diagnosis
• Checking Aftermarket Accessories
• Diagnostic Starting Point - Vibration Diagnosis and Correction
• Diagnostic Starting Point - Rear Differential Carrier
• Diagnostic Starting Point - Wheel Drive Shafts
• Propeller Shaft Replacement
• Lifting and Jacking the Vehicle
• Capacities - Approximate Fluid
• Tire and Wheel Removal and Installation
• Fastener Notice
• Wheel Drive Shaft Replacement - Front
• Transmission Fluid Checking Procedure
• Fluid Leak Diagnosis
• Air Cleaner Intake Duct Replacement
• Catalytic Converter Replacement
• Intermediate Steering Shaft Replacement
• Frame Replacement - Front (W/AWD)
• Transmission Replacement (LA1)
• Transfer Case Description and Operation
• Diagnostic Starting Point - Transfer Case
• Noisy in Drive
• Noisy When Coasting
• Intermittent Noise
• Constant Noise
• Transfer Case Leak Diagnosis

More articles — Transmission