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Power Transfer Unit Case Assemble

Special Tools

Equivalent regional tools: Special Tools 

  1. GM5454066Courtesy of GENERAL MOTORS COMPANY

    Make sure the seal bore is clean and free of oil or dirt.

  2. Using DT-52000  Seal Installer (2) and DT - 8092  Driver Handle (1) to install a NEW Power Transfer Unit Input Shaft Seal- Front (3) with the metal ID portion of the seal facing the inside of the housing.
  3. Install the seal into the bore until the tool bottoms against the case half.
  4. Power Transfer Unit Face Seal (1) - Install NEW
  5. GM5454063Courtesy of GENERAL MOTORS COMPANY

    Make sure the seal bore is clean and free of oil or dirt.

  6. Using DT-51983  Seal Installer (2) and DT - 8092  Driver Handle (1) to install a NEW Power Transfer Unit Input Shaft Seal- Rear (3) with the metal ID portion of the seal facing the DT-51983  Seal Installer (2).
  7. Install the seal into the bore until the tool bottoms against the case half.
  8. GM5453536Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Input Shaft Assembly

    (1) - Install

  9. GM5453528Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Pinion Compression Sleeve (4) - Install

  10. Power Transfer Unit Shift Actuator Shaft (3) - Install
  11. Power Transfer Unit Shift Actuator Gear (2) - Install
  12. Power Transfer Unit Shift Actuator Locker (1) - Install
  13. GM5453534Courtesy of GENERAL MOTORS COMPANY

    Clean the internal threads (no residual pre-applied adhesive allowed)

  14. Power Transfer Unit Cover Housing Seal (3) - Install NEW
    15. CAUTION:

    Refer to Fastener Caution .

    CAUTION:

    This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

  15. Power Transfer Unit Extension Housing (2) - Install
  16. Apply threadlocker to the threads of the NEW bolts. Adhesives, Fluids, Lubricants, and Sealers 
  17. Power Transfer Unit Extension Housing Bolt (1) - Install NEW and tighten [8x] 38.5 N.m (28 lb ft)
  18. GM5453529Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Shift Actuator Seal (4) - Install NEW

  19. Power Transfer Unit Shift Actuator (3) - Install
  20. Power Transfer Unit Shift Actuator Bolt (2) - Install and tighten [2x] 9 N.m (80 lb in)
  21. Power Transfer Unit Shift Actuator Bolt (1) - Install and tighten [2x] 9 N.m (80 lb in)
  22. GM5453539Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Propeller Shaft Seal (3) - Install NEW DT-51467 - A  Seal Installer and DT - 8092  Driver Handle

  23. Power Transfer Unit Propeller Shaft Seal O-Ring (2) - Install NEW
  24. Power Transfer Unit Propeller Shaft Retainer (1) - Install NEW
  25. GM5454048Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Install as an assembly and replace bearing as needed.

    Power Transfer Unit Intermediate Drive Shaft Bearing (2) - Install

  26. Use a press to install the bearing to the power transfer unit intermediate drive shaft.
    27. CAUTION:

    Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

  27. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring (1) - Install [2x]
  28. Power Transfer Unit Intermediate Drive Shaft (4) - Install
  29. Power Transfer Unit Intermediate Drive Shaft Clip (3) - Install
  30. GM5642215Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Intermediate Drive Shaft Housing Seal (3) - Install NEW

  31. Power Transfer Unit Intermediate Drive Shaft Bearing Housing (2) - Install
  32. Power Transfer Unit Cover Housing Bolt (1) - Install and tighten [2x] 38.5 N.m (28 lb ft)
  33. GM5453533Courtesy of GENERAL MOTORS COMPANY

    Lubricate the OD area of the seal with a light film of grease or oil prior to installation.

  34. Power Transfer Unit Cover to Intermediate Drive Shaft Seal (3) - Install NEW DT-51466  Seal Installer and DT - 8092  Driver Handle
  35. Power Transfer Unit Propeller Shaft Seal (2) - Install NEW
  36. Power Transfer Unit Half Shaft Retainer Clip (1) - Install NEW
  37. GM5453538Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The plugs and seals are only available as an assembly. Install a NEW plug with seal during assembly.

    Power Transfer Unit Drain Plug (1) - Install NEW and tighten 40 N.m (30 lb ft)

  38. Tighten the oil fill plug only after the assembly has been filled with fluid. Adhesives, Fluids, Lubricants, and Sealers .
  39. Power Transfer Unit Fill Plug (3) - Install NEW and tighten 40 N.m (30 lb ft)
  40. Apply sealant to the threads of the connector. Adhesives, Fluids, Lubricants, and Sealers 
  41. Power Transfer Unit Vent Hose Connector (2) - Install 20 N.m (15 lb ft)
  42. GM5453531Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Heat Shield (2) - Install

  43. Power Transfer Unit Heat Shield Bolt (1) - Install and tighten [3x] 9 N.m (80 lb in)
  44. GM5453532Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Case (4) Remove @ DT-36842  Transaxle Holding Fixture (3)

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