Transfer Case - Steyr: Diagnosis Pontiac Aztek I

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 . 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 and TRANSFER CASE DESCRIPTION AND OPERATION , and DIFFERENTIAL .

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.

Visual/Physical Inspection

Inspect for aftermarket devices, which could affect the operation of the vehicle. Refer to CHECKING AFTERMARKET ACCESSORIES .

1. Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom.
2. Check for the correct lubricant levels and the proper viscosities.
3. Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed, road conditions, ambient temperature, and other specifics.
4. 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.
5. Inspect for all-wheel drive activation and operation.

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»(ref-181105-S17554207532005100400000)
2. «DIAGNOSTIC STARTING POINT - TRANSFER CASE»(ref-180835-S18640551052005072900000)
3. «DIAGNOSTIC STARTING POINT -- REAR DIFFERENTIAL CARRIER»(ref-167081-S40744093442004100600000)
4. «TROUBLE SHOOTING»(ref-165998-S06895551532004090900000)
5. Noisy In Drive (Scheme 34)
6. Noisy When Coasting (Scheme 36)
7. Intermittent Noise (Scheme 37)
8. Constant Noise (Scheme 38)
9. Transfer Case Leak Diagnosis (Scheme 39)

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Raise the vehicle.
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.

Scheme 40

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.
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.

Scheme 41

Scheme 42

1. Raise and support the vehicle.
2. Disconnect the electrical connector from the speed sensor.
3. Remove the speed sensor/vent hose bolt (3) from the transfer case.
4. Reposition the pinion housing vent hose (2) and mounting bracket away from the speed sensor bolt boss.
5. Remove the speed sensor (1).
6. Remove O-ring from the speed sensor, if necessary. The O-ring may be reused if it is not cut or damaged.

Scheme 43

Scheme 44

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. Lower the vehicle.