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Home >> Buick >> 2007 >> Lucerne CX >> Repair and Diagnosis >> External Pages >> Different car >> Section 245 (Transfer Case - STEYR - Overhaul) >> Repair Instructions >> Transfer Case Assemble >> Extension Housing Assembly and Shim Selection - Procedure A

Extension Housing Assembly and Shim Selection - Procedure A

WARNING: This page is about a different car, the 2006 Pontiac Montana SV6 and 2006 Chevrolet Uplander. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Pressing Outer Bearing Race Into Extension Housing
    GM746870Courtesy of GENERAL MOTORS CORP.
  1. Use the J 44908  (1) and a hydraulic press in order to install the outer bearing race to the extension housing. See Special Tools .
    2. Fig 2: Installing Inner Bearing Race Into Extension Housing
    GM746875Courtesy of GENERAL MOTORS CORP.
  2. Use the J 44908  (1) and a hydraulic press in order to install the inner bearing race to the extension housing. See Special Tools .
    3. Fig 3: Measuring Dimension B Between Flange On Drivenshaft & End Of Pinion
    GM659135Courtesy of GENERAL MOTORS CORP.
  3. Measure the distance between the flange on the drivenshaft and the end of the pinion. Record the value as dimension B.
    4. Fig 4: Pressing Inner Bearing Onto Drivenshaft
    GM659151Courtesy of GENERAL MOTORS CORP.
  4. Use the J 44907  (1) and a hydraulic press in order to install the inner bearing (2) to the drivenshaft. See Special Tools .
    5. Fig 5: View Of Drive Pinion & Extension Housing Assembly
    GM1486595Courtesy of GENERAL MOTORS CORP.
  5. Install the drivenshaft (3) and NEW spacer (1) into the extension housing (2).
    6. Fig 6: Installing Bearing Onto Shaft Using J 5590
    GM659152Courtesy of GENERAL MOTORS CORP.
  6. Use the J 5590  (1) and a hydraulic press in order to install the bearing onto the shaft.
    7. Fig 7: Installing Extension Housing Oil Seal Using J 36797-A
    GM746877Courtesy of GENERAL MOTORS CORP.
  7. Use the J 36797-A  (1) in order to install a new oil seal (2) into the extension housing (3). See Special Tools .
    8. Fig 8: Pressing Flange Onto Extension Housing Assembly
    GM659154Courtesy of GENERAL MOTORS CORP.
  8. Lightly lubricate the splines of the drivenshaft with grease.
  9. Install the flange (1) onto the shaft using a hydraulic press.
    10. Fig 9: Installing Extension Housing Assembly & Bolts To J 44755
    GM746838Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  10. Install the extension housing assembly (3) and bolts (1) to the J 44755  (2). See Special Tools .

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    11. Fig 10: Removing Flange Nut
    GM630580Courtesy of GENERAL MOTORS CORP.
  11. Install a new nut (1) onto the shaft.

    Tighten: 

    • Tighten the nut, with new bearings to 250 N.m (185 lb ft).
    • Tighten the nut, with used bearings to 200 N.m (148 lb ft).

  12. Remove the extension housing assembly and bolts from the J 44755  . See Special Tools .
    13. Fig 11: Measuring Rotating Torque Of Drivenshaft
    GM754966Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Loosening the pinion nut to achieve proper rotating torque requires replacement with a new spacer.
  13. Measure in both directions, the rotating torque of the drivenshaft. A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 N.m (13 lb in). When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly. Tighten the flange nut as required to achieve the proper rotating torque value.
    14. Fig 12: Measuring Dimension C
    GM659142Courtesy of GENERAL MOTORS CORP.
  14. Measure the distance between the end of the pinion and the extension housing seal surface. Record the value as dimension C.
    15. Fig 13: Installing J 44757-3 Into Extension Housing
    GM659136Courtesy of GENERAL MOTORS CORP.
  15. Install the J 44757-3 (2) into the bore of the housing (1).
    16. Fig 14: Installing J 44757-9 & Bolts To Housing
    GM659138Courtesy of GENERAL MOTORS CORP.
  16. Install J 44757-9 (3) and bolts (2) to the housing (1).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    17. Fig 15: Measuring Dimension D
    GM659140Courtesy of GENERAL MOTORS CORP.
  17. Measure the distance (x) between the J 44757-3 and the J 44757-9 using a feeler gage. Add the measured value (x) to 67.3 mm (2.65 in). Record the value as dimension D.
    18. Fig 16: Identifying Drivenshaft Etched Marks
    GM754867Courtesy of GENERAL MOTORS CORP.
  18. Determine if the drivenshaft has a plus, minus or zero value etched onto the end of the gear.

    Note that the handwritten 1 (1) and 7 (2) are similar. The 7 (2) will have a line drawn through the number. A comma is to be considered a decimal point.

  19. Calculate the extension housing shim thickness. Refer to the Extension Housing Shim Calculation Table - Procedure A in General Specifications .
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