LEMON Manuals: Even more car manuals for everyone
Home >> Buick >> 2007 >> Lucerne CX >> Repair and Diagnosis >> External Pages >> Different car >> Section 245 (Transfer Case - STEYR - Overhaul) >> Repair Instructions >> Transfer Case Disassemble >> Disassembly Procedure

Disassembly Procedure

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: View Of Fill & Drain Plugs
    GM630583Courtesy of GENERAL MOTORS CORP.
  1. Remove the drain plug (1) from the extension housing. Allow the gear oil to drain.
    2. Fig 2: Identifying Drain Plug
    GM630590Courtesy of GENERAL MOTORS CORP.
  2. Remove the drain plug (1) from the left case. Allow the transmission oil to drain.
    3. Fig 3: Installing J 44755 Onto Transfer Case Assembly
    GM746869Courtesy of GENERAL MOTORS CORP.
  3. Install the transfer case assembly (1) onto the J 44755  (3). See Special Tools . Position the carrier onto the post of the fixture.
    4. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the retaining bolts (2).

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    5. Fig 4: View Of Transfer Case Hose/Clamp Assembly, Vent Hose, Bracket & Bolt
    GM630581Courtesy of GENERAL MOTORS CORP.
  5. Remove the hose and clamp assembly (1), vent hose with bracket (2) and bolt (3).
    6. Fig 5: Locating Speed Sensor
    GM630579Courtesy of GENERAL MOTORS CORP.
  6. Remove the speed sensor (1).
  7. Remove the O-ring seal from the sensor, if required. The O-ring seal may be reused if not cut or damaged.
    8. Fig 6: Identifying Extension Housing Assembly, Shim & Bolts
    GM630584Courtesy of GENERAL MOTORS CORP.
  8. Remove the extension housing assembly (1), bolts (3) and shim (2). Mark or tag the shim for assembly.
    9. Fig 7: Measuring Rotating Torque Of Drivenshaft
    GM754966Courtesy of GENERAL MOTORS CORP.
  9. If reusing the drivenshaft bearings, measure in both directions, the rotating torque of the drivenshaft and record the value for assembly.
    10. Fig 8: Identifying J 44755
    GM746838Courtesy of GENERAL MOTORS CORP.
  10. Install the extension housing assembly (3) and the M8 x 1.25 bolts (1) to the J 44755  (2). See Special Tools .

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

    11. Fig 9: Removing Flange Nut
    GM630580Courtesy of GENERAL MOTORS CORP.
  11. Remove the nut (1).
  12. Remove the extension housing assembly and bolts from J 44755  . See Special Tools .
    13. Fig 10: Aligning Extension Housing Assembly Into Press
    GM630586Courtesy of GENERAL MOTORS CORP.
  13. Position the extension housing assembly into a press.
    14. Fig 11: Identifying Extension Housing Components
    GM630587Courtesy of GENERAL MOTORS CORP.
  14. Remove the flange (1), spacer (5) and shaft (9) from the housing (6). Discard the spacer (5).
  15. Remove the oil seal (2) and bearing (3).
    16. Fig 12: View Of J 44380 & J 2619-01 Removing The Bearing Races From The Housing
    GM746858Courtesy of GENERAL MOTORS CORP.
  16. Use the J 44380  (2) and the. See Special Tools .J 2619-01  (1) in order to remove the bearing races from the housing (3), if required.
    17. Fig 13: Installing J 22912-01 Onto Shaft To Remove Bearing
    GM630582Courtesy of GENERAL MOTORS CORP.
  17. Install J 22912-01  (1) or equivalent onto the shaft.
  18. Position the shaft into a press.
  19. Remove the bearing from the shaft.
    20. Fig 14: Locating Left Case Bolts
    GM630588Courtesy of GENERAL MOTORS CORP.
  20. Remove the bolts (1 and 5), housing (2), shim (3) and O-ring seal (4) from the left case. Mark or tag the shim for assembly.
    21. Fig 15: Identifying Case Bolts
    GM630591Courtesy of GENERAL MOTORS CORP.
  21. Remove the bolts (1) from the case.
    22. Fig 16: View Of J 44755 Installed To Left Case
    GM630592Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When separating the case halves, avoid damage to the sealing surfaces. Do not insert a screwdriver or prying tool between the case sealing surfaces.
  22. Rotate the J 44755  90 degrees. See Special Tools .
  23. Separate the right case (2) from the left case (1).
    24. Fig 17: View Of Idler Gear
    GM630596Courtesy of GENERAL MOTORS CORP.
  24. Remove the idler gear (1) from the right case.
    25. Fig 18: Identifying Idler Gear Long Flange Area
    GM659130Courtesy of GENERAL MOTORS CORP.
  25. Note the installed position of the idler gear. The side of the gear with the longer flange area (1) is to be installed to the right case.
    26. Fig 19: View Of J 22912-01 & Idler Gear
    GM746835Courtesy of GENERAL MOTORS CORP.
  26. Install the J 22912-01  (1) onto the gear (2).
  27. Position the gear into a press.
    28. Fig 20: Idler Gear Components
    GM659131Courtesy of GENERAL MOTORS CORP.
  28. Remove the bearings (1 and 3) from the gear (2).
    29. Fig 21: Identifying Left Case & J 44755
    GM746840Courtesy of GENERAL MOTORS CORP.
  29. Install the left case (2) onto the J 44755  (1). See Special Tools . Align the notched area of the tool with the flat areas of the driveshaft.
    30. Fig 22: Locating Driveshaft Nut
    GM630593Courtesy of GENERAL MOTORS CORP.
  30. Remove the nut (1) from the driveshaft.
    31. Fig 23: Aligning Left Case In A Press
    GM630594Courtesy of GENERAL MOTORS CORP.
  31. Position the left case into a press.
    32. Fig 24: Identifying Left Case Components
    GM1486537Courtesy of GENERAL MOTORS CORP.
  32. Remove the gear (2), bearing (3), shim (4) and shaft (1) from the left case. Mark or tag the shim for assembly.
    33. Fig 25: Installing J 44380 & J 2619-01 In Left Case
    GM746861Courtesy of GENERAL MOTORS CORP.
  33. Use the J 44380  (2) and the J 2619-01  (1) in order to remove the outer bearing race from the left case (3). See Special Tools .
    34. Fig 26: Removing Inner Bearing Race
    GM1486545Courtesy of GENERAL MOTORS CORP.
  34. Remove the inner bearing race from the left case.
    35. Fig 27: Locating Left Case Oil Seals
    GM1486552Courtesy of GENERAL MOTORS CORP.
  35. Remove the oil seals (1) from the left case.
    36. Fig 28: Installing J 22912-01 Onto Shaft To Remove Bearing
    GM630582Courtesy of GENERAL MOTORS CORP.
  36. Install the J 22912-01  (1) or equivalent onto the shaft.
  37. Position the shaft into a press.
  38. Remove the bearing from the shaft.
    39. Fig 29: View Of Left Case Idler Gear Bearing Race
    GM746844Courtesy of GENERAL MOTORS CORP.
  39. Install J 44380  (2) into the left case idler gear bearing race. See Special Tools .
  40. Install J 2619-01  (1) to J 44380  (2). See Special Tools .
    41. Fig 30: Locating Idler Gear Bearing Race
    GM754865Courtesy of GENERAL MOTORS CORP.
  41. Remove the idler gear bearing race (1) from the left case.
    42. Fig 31: Identifying Right Case & J 44755
    GM746847Courtesy of GENERAL MOTORS CORP.
  42. Install the right case (1) onto the J 44755  (2). See Special Tools . Position the carrier onto the post of the fixture.
    43. Fig 32: View Of Right Case Oil Seal
    GM630589Courtesy of GENERAL MOTORS CORP.
  43. Remove the oil seal (1) from the right case.
    44. Fig 33: Locating Differential Carrier Nut
    GM630597Courtesy of GENERAL MOTORS CORP.
  44. Remove the nut (1) from the carrier.
    45. Fig 34: Aligning Right Case Into Press
    GM630598Courtesy of GENERAL MOTORS CORP.
  45. Position the right case into a press.
  46. Install the J 5590  (1) to the differential carrier.
    47. Fig 35: View Of Carrier, Bearing & J 44757-4
    GM1486583Courtesy of GENERAL MOTORS CORP.
  47. Remove the bearing (1), shim (3) and differential carrier (4) from the right case (2). Mark or tag the shim for assembly.
    48. Fig 36: Identifying J 44380 & J 2619-01
    GM746865Courtesy of GENERAL MOTORS CORP.
  48. Use the J 44380  (2) and the. See Special Tools .J 2619-01  (1) in order to remove the bearing races from the right case (3), if required.
    49. Fig 37: View Of J 44754 On Differential Carrier Bearing
    GM746849Courtesy of GENERAL MOTORS CORP.
  49. Install the J 44754  (1) over the differential carrier bearing. See Special Tools .
    50. Fig 38: Assembling J 22912-01 & J 44754
    GM746852Courtesy of GENERAL MOTORS CORP.
  50. Install the J 22912-01  (3) over the J 44754  (2). See Special Tools . Tighten until snug.
  51. Position the carrier and J 5590  (1) into a press in order to remove the bearing.
    52. Fig 39: Inserting J 44380 Into Right Case Idler Gear Bearing Race
    GM746853Courtesy of GENERAL MOTORS CORP.
  52. Install the J 44380  (2) into the right case idler gear bearing race. See Special Tools .
  53. Install J 2619-01  (1) to J 44380  (2). See Special Tools .
    54. Fig 40: Identifying Right Case Idler Gear Bearing Race & Shim
    GM659159Courtesy of GENERAL MOTORS CORP.
  54. Remove the bearing race (1) and shim (2). Mark or tag the shim for assembly.
    55. Fig 41: Inserting J 44737 Into Driveshaft Bearing
    GM746855Courtesy of GENERAL MOTORS CORP.
  55. Install the J 44737  (2) into the driveshaft bearing. Tighten the tool until snug.
  56. Install the J 2619-01  (1) to the J 44737  (2).
    57. Fig 42: Identifying Right Case Idler Gear Bearing Race
    GM659159Courtesy of GENERAL MOTORS CORP.
  57. Remove the bearing (3) from the right case.
    58. Fig 43: View Of Differential Carrier Roll Pin & Shaft
    GM630600Courtesy of GENERAL MOTORS CORP.
  58. Remove the roll pin (2) and shaft (1) from the differential carrier, if required.
    59. Fig 44: Identifying Differential Carrier Gears & Washers
    GM630603Courtesy of GENERAL MOTORS CORP.
  59. Remove the side gears (2), pinion gears (3) and washers (1 and 4) from the carrier, if required.
    60. Fig 45: Locating Differential Carrier Gears & Components
    GM630604Courtesy of GENERAL MOTORS CORP.
  60. Remove the ring (10) from the carrier, if required.
  61. Remove the pin (9), gear (3) and washers (1, 2, 7 and 8) from the carrier, if required.
  62. Remove the needle bearings (4 and 6) and washer (5) from the gear (3), if required.
scientia non olet · About LEMON Manuals