Transfer Case - Steyr: Other Pontiac Aztek I

Intermittent

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

Tools Required

1. J 2619-01 Slide Hammer
2. J 23129 Universal Seal Remover
3. J 29794 Axle Shaft Remover Extension
4. J 44752 Bearing, Race, and Seal Installer Removal Procedure

Scheme 45

1. Raise and support the vehicle.
2. Remove the right front tire and wheel assembly.
3. Remove the right front wheel drive shaft. Refer to «AXLE SHAFT»(ref-165998-S08293195952004090900000) .
4. Using the J 2619-01 with the J 29794 and the J 23129 remove the axle shaft oil seal (1) from the transfer case.

Scheme 46

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. Important: 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.
4. Install the right front tire and wheel assembly.
5. Lower the vehicle.
6. Inspect the transaxle fluid level. Refer to «CHECKING FLUID LEVEL & CONDITION»(ref-153939-S12170600872003042900000).
7. Inspect for fluid leaks. see scheme 6

1. J 36797 Getrag Axle Output Shaft Seal Installer
2. J 44755 Holding Fixture Removal Procedure

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1. Raise and support the vehicle.
2. Remove the extension housing vent hose (2) and clamp. Refer to «VENT HOSE ASSEMBLY REPLACEMENT»(ref-180835-S34952892132005072900000) .
3. Remove the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-180831-S29044290832005072900000) .
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. Install the extension housing assembly (3) to the J 44755 (2) with M8 x 1.25 bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft).
8. Remove the flange nut (1).
9. Remove the bolts and the extension housing assembly from the J 44755.
10. Position the extension housing assembly into a press.
11. Press the pinion shaft from the flange.
12. Remove and discard the extension housing seal.

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1. Use the J 36797 in order to install a new oil seal (2) into the extension housing.
2. Position the flange and the extension housing assembly into a press.
3. Lightly lubricate the splines on the driven shaft.
4. Press the flange (1) onto the driven shaft.
5. Install the extension housing assembly to the J 44755 (2) using M8x 1.25 bolts (1). Tighten Tighten the bolts to 25 N.m (18 lb ft).
6. Install the flange nut (1) onto the driven shaft. Tighten Tighten the flange nut to 250 N.m (185 lb ft).
7. Remove the extension housing assembly from the J 44755.
8. Measure the rotating torque of the driven shaft in both directions. Specification The driven shaft and bearings should have a rotating torque of 1.5 N.m (13 Ib. in).
9. Apply sealant GM P/N United States 12346004 GM P/N Canada 10953480, or equivalent to both sides of the shim.
10. Align the reference marks and install the shim (2) to the transfer case.
11. 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).
12. Install the extension housing drain plug (1) and gasket to the extension housing. Tighten Tighten the plug to 32 N.m (24 Ib. in).
13. Remove the extension housing fill plug (2) and gasket.
14. Fill the extension housing with gear oil. Refer to «TRANSFER CASE FLUID REPLACEMENT»(ref-180835-S10450938322005072900000) .
15. Install the extension housing fill plug and gasket. Tighten Tighten the plug to 28 N.m (21 Ib. in).
16. Install the vent hose (2) and clamp (1). Refer to «VENT HOSE ASSEMBLY REPLACEMENT»(ref-180835-S34952892132005072900000) .
17. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-180831-S29044290832005072900000) .
18. Lower the vehicle.

Scheme 61

1. Raise and support the vehicle.
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.

Scheme 62

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.

Scheme 63

1. Raise and support the vehicle.
2. Remove the transaxle brace bolts.
3. Remove the transaxle brace.

Scheme 64

Scheme 65

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. J 36660-A Torque Angle Meter
2. J 44467 Slide Hammer
3. J 6125-1B Slide Hammer Adapter
4. J 44755 Holding Fixture Removal Procedure

Important: Transmission 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.

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1. Raise and support the vehicle.
2. Remove the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-180831-S29044290832005072900000) .
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»(ref-180835-S16764377532005072900000) .
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. NOTE: Removal and installation of the transfer case while the transmission 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, transmission, and/or the transfer case will be damaged.
10. Remove the transfer case with the transaxle. Refer to «TRANSAXLE»(ref-154467-S39133999092003051500000) .
11. Install the transaxle to the transmission support fixture.
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). CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly. NOTE: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.
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.
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.
21. Install the J 44467 into the snap ring groove on the output shaft (510) and tighten securely.
22. Use the J6125-1Band the J 44467 to remove the output shaft.
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. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906). Installation Procedure Important: If 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 appropriate Transmission article. 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. Install a new seal transfer case seal (1). Rotate the transaxle 90 degrees. CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly. Install the transfer case to the transaxle. Install the transfer case bolts (1) and (2). Tighten 5.1. Tighten the bolts to 35 N.m (26 lb ft). 5.2. Use the J 36660-A to rotate the bolts 160 degrees. Install the transfer case bolt (3). Tighten 6.1. Tighten the bolt to 35 N.m (26 lb ft). 6.2. Use the J 36660-A to rotate the bolts 70 degrees. Install the transfer case bolts (4) and (5). Tighten Tighten the bolts to 40 N.m (30 lb ft). Install the transfer case side brace (905). Install and tighten the transfer case side brace bolts in the order shown. Tighten Tighten transfer case side brace bolts to 32N.m (24 lb ft). Install the transfer case lower brace to transaxle bolt (1). Tighten Tighten the bolt to 56N.m (42 lb ft). Tighten the transfer case lower brace to transfer case bolts (903). Tighten Tighten the bolts to 32N.m (24 lb ft). Install the output shaft to the transmission. Install a new output shaft retaining ring (1). Install the transaxle with the transfer case. Refer to «TRANSAXLE»(ref-154467-S39133999092003051500000) . Install the vent hose (2) and the clamp (1) to the transfer case. Install the vehicle speed sensor electrical connector. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT»(ref-180831-S29044290832005072900000) . Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to «TRANSFER CASE FLUID REPLACEMENT»(ref-180835-S10450938322005072900000) . Install the drain plug (1) and gasket to the case. Tighten Tighten the drain plug to 32 N.m (24 lb ft). Install the transfer case lower brace. Refer to «SUPPORT BRACE REPLACEMENT»(ref-180835-S16764377532005072900000) . Lower the vehicle. Inspect and adjust the transmission fluid level.

Scheme 86

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.

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