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Home >> Pontiac >> 2004 >> Aztek Base, FWD >> Repair and Diagnosis >> Transmission >> Transfer Case - STEYR >> Repair Instructions >> Transfer Case and/or Seal Replacement >> Installation Procedure

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 Automatic Transmission - 4T65-E Unit Repair.
    Fig 1: View Of Transfer Case Lower Brace Bolts & Brace
    GM630829Courtesy of GENERAL MOTORS CORP.
  1. 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.
    2. Fig 2: Locating Transfer Case Seal
    GM692591Courtesy of GENERAL MOTORS CORP.
  2. Install a new seal transfer case seal (1).
    3. Fig 3: Identifying Oil Dam
    GM630839Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The oil dam (901) must be installed with the notch aligned to the oil passage in the transaxle case (1).
  3. Install the oil dam (901) to the transaxle.
    4. Fig 4: Installing Transfer Case To Transaxle
    GM621064Courtesy of GENERAL MOTORS CORP.
    CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
  4. Rotate the transaxle 90 degrees.
  5. Install the transfer case to the transaxle.
    6. Fig 5: Identifying Transfer Case Bolts
    GM677381Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the transfer case bolts (1) and (2).

    Tighten: 

    1. Tighten the bolts to 35 N.m (26 lb ft).
    2. Use the J 36660-A  to rotate the bolts 160 degrees. See Special Tools and Equipment .

  7. Install the transfer case bolt (3).

    Tighten: 

    1. Tighten the bolt to 35 N.m (26 lb ft).
    2. Use the J 36660-A  to rotate the bolts 70 degrees. See Special Tools and Equipment .

  8. Install the transfer case bolts (4) and (5).

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    9. Fig 6: View Of Transfer Case Side Brace
    GM677386Courtesy of GENERAL MOTORS CORP.
  9. Install the transfer case side brace (905).
  10. Install and tighten the transfer case side brace bolts in the order shown.

    Tighten:  Tighten transfer case side brace bolts to 32 N.m (24 lb ft).

    11. Fig 7: Identifying Transaxle Bolt
    GM692586Courtesy of GENERAL MOTORS CORP.
  11. Install the transfer case lower brace to transaxle bolt (1).

    Tighten:  Tighten the bolt to 56 N.m (42 lb ft).

    12. Fig 8: Locating Transfer Case Lower Brace To Transfer Case Bolts
    GM659370Courtesy of GENERAL MOTORS CORP.
  12. Tighten the transfer case lower brace to transfer case bolts (903).

    Tighten:  Tighten the bolts to 32 N.m (24 lb ft).

  13. Install the output shaft to the transmission. Refer to Output Shaft Assemble in Automatic Transaxle - 4T65-E Unit Repair.
    14. Fig 9: Locating Left Output Shaft Retaining Ring
    GM692584Courtesy of GENERAL MOTORS CORP.
  14. Install a new output shaft retaining ring (1).
  15. Install the transaxle with the transfer case. Refer to Transmission Replacement (LA1) or Transmission Replacement (LY7) in Automatic Transaxle - 4T65-E.
    16. Fig 10: View Of Transfer Case Hose/Clamp Assembly, Vent Hose, Bracket & Bolt
    GM630581Courtesy of GENERAL MOTORS CORP.
  16. Install the vent hose (2) and the clamp (1) to the transfer case.
  17. Install the vehicle speed sensor electrical connector.
  18. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  19. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to Transfer Case Fluid Replacement .
    20. Fig 11: Identifying Drain Plug
    GM630590Courtesy of GENERAL MOTORS CORP.
  20. Install the drain plug (1) and gasket to the case.

    Tighten:  Tighten the drain plug to 32 N.m (24 lb ft).

  21. Install the transfer case lower brace. Refer to Support Brace Replacement (LA1)  or Support Brace Replacement (LY7) .
  22. Lower the vehicle.
  23. Inspect and adjust the transmission fluid level. Refer to Transmission Fluid Checking Procedure in Automatic Transaxle - 4T65-E.
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