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Transfer Case - Removal & Installation: Other Pontiac Aztek I

Transfer Case 21 illustrations ~1224 words

TRANSAXLE-TO-TRANSFER CASE END PLAY

Note. Tools required: Assembly Lubricant (or equivalent) (J-36850) and End Play Checking Tool (J-44472).

Note. Transaxle oil circulates between the transaxle assembly and the transfer case. In situations where transaxle related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned and inspected for damage.

Scheme 13

Scheme 13: TRANSAXLE-TO-TRANSFER CASE END PLAY
Scheme 13: TRANSAXLE-TO-TRANSFER CASE END PLAY

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Position the transaxle so that the case side cover is facing down.
  2. Install the final drive sun gear shaft. (Scheme 13) CAUTION: The park gear thrust bearing must be retained in the park gear when installing the transfer case to the transaxle, or damage may occur.
  3. Use assembly lubricant or equivalent in order to retain the parking gear thrust bearing to the parking gear. Install the parking gear thrust bearing and the parking gear. (Scheme 14) NOTE: The counterbore on the final drive sun gear installs towards the parking gear.
  4. Install the final drive sun gear. (Scheme 15)
  5. Install the gauge bar (1) onto the case mounting surface. (Scheme 16) NOTE: Install bolts to end play checking tool and tighten securely to prevent tool deflection during end play measurement.
  6. Install end play checking tool onto the transaxle. Tighten end play checking tool to remove end play. Hand tighten only.
  7. Measure the distance from the case mounting surface, bottom of the gauge bar (1) to the top of the final drive sun gear. (Scheme 16) This measurement is dimension "A". (Scheme 17)
  8. Remove the gauge bar (1) and end play checking tool.
  9. Install the gauge bar onto the carrier.
  10. Measure the distance from the bottom of the gauge bar to the transfer case. (Scheme 18) This measurement is dimension "B1".
  11. Measure the distance from the bottom of the gauge bar to the thrust bearing (1). (Scheme 19) This measurement is dimension "B2".
  12. Subtract dimension "B2" from dimension "B1". This dimension is "B". (Scheme 17)
  13. Remove the gauge bar from the transfer case.
  14. Remove the final drive sun gear. (Scheme 15)
  15. Install the selective washer. (Scheme 20) NOTE: The counterbore on the final drive sun gear installs towards the parking gear.
  16. Install the final drive sun gear. (Scheme 15)
WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
CAUTIONUse the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Scheme 21

Scheme 21: Removal
Scheme 21: Removal

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Raise the vehicle.
  2. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  3. Remove the drain plug drain the transfer case oil. See appropriate SERVICING article.
  4. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
  5. Remove the transfer case brace. See REMOVAL & INSTALLATION in appropriate SERVICING article.
  6. Remove the vent tube clamp. (Scheme 21)
  7. Separate the vent tube from the vent tube bracket.
  8. Remove the vent tube from the transfer case. CAUTION: Removal and installation of the transfer case while the transaxle 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, transaxle, and/or the transfer case will be damaged.
  9. Remove the transfer case with the transaxle. Refer to appropriate REMOVAL & INSTALLATION article as follows: See «REMOVAL & INSTALLATION - AZTEK & RENDEZVOUS»(ref-154467) article in AUTOMATIC TRANSMISSIONS. See REMOVAL & INSTALLATION - MONTANA, SILHOUETTE & VENTURE article in AUTOMATIC TRANSMISSIONS.
  10. Install the transaxle to appropriate transaxle support fixture.
  11. Remove and discard the left output shaft retaining ring. (Scheme 22)
  12. Rotate the transaxle 90 degrees so that the transaxle side cover is facing down. (Scheme 23)
  13. Rotate the transaxle 90 degrees.
  14. Remove the transfer case side brace bolts (1-5), and the transfer case side brace. (Scheme 24)
  15. Remove the transfer case bolts (1-5). (Scheme 25) WARNING: This component weighs approximately 60 pounds. Personal injury may result if you lift the component improperly. CAUTION: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.
  16. Remove the transfer case with the output shaft from the transaxle. (Scheme 26)
  17. Install the transfer case assembly to the Holding Fixture (J-44755). (Scheme 27)
  18. Install the retaining bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  19. Attach the Slide Hammer Adapter (J-6125-1B) to the Slide Hammer (J-44467). (Scheme 28)
  20. Install the slide hammer into the snap ring groove on the output shaft and tighten securely.
  21. Use the slide hammer adapter and the slide hammer to remove the output shaft.
  22. Remove the output shaft from the transfer case.
  23. Remove the transfer case seal from the transfer case. (Scheme 29)
  24. Remove the oil dam from the transaxle. (Scheme 30)
  25. If you are replacing the transfer case, remove the transfer case lower brace bolts and the lower brace. (Scheme 31)

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Note. If you are replacing anything other than gaskets or seals, the transaxle-to-transfer case end play check must be performed. See TRANSAXLE-TO-TRANSFER CASE END PLAY under ADJUSTMENTS.

Scheme 32

Scheme 32: Installation
Scheme 32: Installation

Scheme 33

Scheme 33
Scheme 33
  1. If you are replacing the transfer case, install the transfer case lower brace and lower brace bolts. DO NOT tighten the bolts. (Scheme 31)
  2. Install a NEW transfer case seal. (Scheme 29) NOTE: The oil dam must be installed with the notch aligned to the oil passage in the transaxle case. (Scheme 30)
  3. Install the oil dam to the transaxle.
  4. Rotate the transaxle 90 degrees. WARNING: This component weighs approximately 60 pounds. Personal injury may result if you lift the component improperly.
  5. Install the transfer case to the transaxle. (Scheme 32)
  6. Install the transfer case bolts (1) and (2). (Scheme 25) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000). Use the Torque Angle Meter Tool (J-36660-A) to rotate the bolts 160 degrees.
  7. Install the transfer case bolt (3). (Scheme 25) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000). Use the torque angle meter tool to rotate the bolts 70 degrees.
  8. Install the transfer case bolts (4) and (5). (Scheme 25) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  9. Install the transfer case side brace. (Scheme 24)
  10. Install and tighten the transfer case side brace bolts in the order shown. (Scheme 24) Tighten transfer case side brace bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  11. Install the transfer case lower brace to transaxle bolt. (Scheme 23) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  12. Tighten the transfer case lower brace to transfer case bolts. (Scheme 33) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  13. Install the output shaft to the transaxle.
  14. Install a new output shaft retaining ring. (Scheme 22)
  15. Install the transaxle with the transfer case. Refer to appropriate REMOVAL & INSTALLATION article as follows: See «REMOVAL & INSTALLATION»(ref-154467) - AZTEK & RENDEZVOUS article in AUTOMATIC TRANSMISSIONS. See REMOVAL & INSTALLATION - MONTANA, SILHOUETTE & VENTURE article in AUTOMATIC TRANSMISSIONS.
  16. Install the vent hose (2) and the clamp (1) to the transfer case. (Scheme 21)
  17. Install the vehicle speed sensor electrical connector. Tighten the engine brace mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155030-S25995410682003060500000).
  18. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  19. Install the transfer case drain plug and fill the transfer case with appropriate fluid to proper level. See appropriate SERVICING article.
  20. Install the transfer case lower brace. See REMOVAL & INSTALLATION in appropriate SERVICING article.
  21. Lower the vehicle.
  22. Inspect and adjust the transaxle fluid to appropriate level. See appropriate SERVICING article in AUTOMATIC TRANSMISSIONS.

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