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Transfer Case - Servicing: Removal & Installation Pontiac Aztek I

Transfer Case 11 illustrations ~880 words

REMOVAL & INSTALLATION

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 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.

Note. Use correct fastener in correct location. Replacement fasteners must be correct part number for that application. Fasteners requiring replacement or fasteners requiring use of thread locking compound or sealant are identified in 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 correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Note. See REMOVAL & INSTALLATION - AZTEK, MONTANA, RENDEZVOUS, SILHOUETTE & VENTURE article.

Removal

  1. Raise and support the vehicle.
  2. Remove the right front tire and wheel assembly.
  3. Remove the right front wheel drive shaft. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  4. Using Slide Hammer (J-2619-O1) with Axle Shaft Remover Extension (J-29794) and Universal Seal Remover (J-23129), remove axle shaft oil seal (1) from transfer case. (Scheme 1)

Scheme 1

Scheme 1
Scheme 1

Installation

  1. Lubricate the lip of the axle shaft oil seal with automatic transaxle fluid.
  2. Using Bearing, Race, and Seal Installer (J-44752), install axle shaft oil seal to the transfer case. CAUTION: Carefully guide the axle shaft past the axle shaft oil seal. Do not allow the shaft splines to contact any portion of the sealing surface or damage to the oil seal can occur.
  3. Install the right front wheel drive shaft. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  4. Install the right front tire and wheel assembly. Tighten wheel lug nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000) .
  5. Lower the vehicle.
  6. Inspect the transaxle fluid level. See «LUBRICATION»(ref-154798-S33488020732003052700000) .
  7. Inspect for fluid leaks.

Scheme 2

Scheme 2
Scheme 2
  1. Raise and support vehicle.
  2. Remove extension housing vent hose and clamp. See «VENT HOSE»(ref-154798-S35608363462003052800000).
  3. Remove drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  4. Place a container under extension housing.
  5. Remove lubricant drain plug (1) and gasket. see scheme 1 Allow oil to drain.
  6. Remove bolts (3), extension housing assembly (1), and shim (2) from transfer case. Reference mark shim for proper reassembly. (Scheme 3)
  7. Install extension housing assembly (3) to Holding Fixture (J-44755) (2) with M8 x 1.25 bolts. (Scheme 4) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  8. Remove flange nut (1). (Scheme 5)
  9. Remove bolts and extension housing assembly from holding fixture.
  10. Position extension housing assembly into press.
  11. Press pinion shaft from flange. (Scheme 6)
  12. Remove and discard extension housing seal.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. Using Getrag Axle Output Shaft Seal Installer (J-36797), install NEW oil seal (2) into extension housing. (Scheme 7)
  2. Position flange and extension housing assembly into press.
  3. Lightly lubricate splines on driven shaft.
  4. Press flange (1) onto driven shaft. (Scheme 8)
  5. Install extension housing assembly to holding fixture (2) using M8 x 1.25 bolts (1). (Scheme 4) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  6. Install flange nut (1) onto driven shaft. (Scheme 5) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  7. Remove extension housing assembly from holding fixture.
  8. Using INCH-lb. torque wrench, measure rotating torque of driven shaft in both directions. Ensure rotating torque is 13 INCH lbs. (1.5 N.m).
  9. Apply sealant to both sides of shim.
  10. Align reference marks and install shim (2) to transfer case. (Scheme 3)
  11. Install extension housing (1) and bolts (3) to shim and transfer case. (Scheme 3) Tighten to specification «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  12. Install extension housing drain plug (1) and gasket to extension housing. see scheme 1 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  13. Remove extension housing fill plug (2) and gasket. see scheme 1
  14. Fill extension housing with appropriate fluid to proper level. See «LUBRICATION»(ref-154798-S33488020732003052700000).
  15. Install extension housing fill plug and gasket. see scheme 1 Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  16. Install vent hose (2) and clamp (1). See «VENT HOSE»(ref-154798-S35608363462003052800000).
  17. Install drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  18. Lower vehicle.

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Raise and support vehicle.
  2. Disconnect electrical connector from the speed sensor.
  3. Remove speed sensor/vent hose bolt from transfer case. See «VENT HOSE»(ref-154798-S35608363462003052800000).
  4. Reposition pinion housing vent hose and mounting bracket away from speed sensor bolt boss. See «VENT HOSE»(ref-154798-S35608363462003052800000).
  5. Remove speed sensor (1). (Scheme 9)
  6. Remove O-ring from speed sensor, if necessary (2). The O-ring may be reused if not cut or damaged. (Scheme 9)

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Install O-ring to speed sensor, if removed.
  2. Install speed sensor (1) to transfer case. (Scheme 9)
  3. Position pinion housing vent hose (2) and mounting bracket to speed sensor bolt boss. See «VENT HOSE»(ref-154798-S35608363462003052800000).
  4. Install speed sensor bolt (3) to transfer case. (Scheme 10) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000).
  5. Connect electrical connector to speed sensor.
  6. Lower vehicle.
  1. Raise and support the vehicle.
  2. Remove the transaxle brace bolts. (Scheme 11)
  3. Remove the transaxle brace.

Scheme 11

Scheme 11
Scheme 11
  1. Install the transaxle brace.
  2. Install the transaxle brace bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154798-S31990664812003052700000) .
  3. Lower the vehicle.
  1. Raise and support vehicle.
  2. Release vent hose clamp (1) from extension housing assembly. (Scheme 10)
  3. Disconnect vent hose (2) from retaining bracket on transfer case assembly. (Scheme 10)
  4. Remove vent hose from extension housing assembly vent tube by carefully twisting hose.
  1. Install vent hose to extension housing assembly vent tube.
  2. Connect vent hose (2) to retaining bracket on transfer case assembly. (Scheme 10)
  3. Install vent hose clamp (1) to extension housing assembly. (Scheme 10)
  4. Lower the vehicle.

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