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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1124 (Transfer Case - STEYR) >> Repair Instructions >> Drive Pinion Flange/Yoke and/or Oil Seal Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Drive Pinion & Extension Housing Assembly
    GM1486595Courtesy of GENERAL MOTORS CORP.
  1. Install the drive pinion (3) and NEW spacer (1) into the extension housing (2).
    2. Fig 2: View Of J 5590
    GM659152Courtesy of GENERAL MOTORS CORP.
  2. Use the J 5590 (1) and a hydraulic press in order to install the bearing onto the shaft.
    3. Fig 3: Identifying J 36797-A
    GM746877Courtesy of GENERAL MOTORS CORP.
  3. Use the J 36797-A  in order to install a new oil seal (2) into the extension housing. See Special Tools and Equipment .
    4. Fig 4: Pressing Flange Onto Extension Housing Assembly
    GM659154Courtesy of GENERAL MOTORS CORP.
  4. Position the flange and the extension housing assembly into a press.
  5. Lightly lubricate the splines on the driven shaft.
  6. Press the flange (1) onto the driven shaft.
    7. Fig 5: Identifying J 44755
    GM746838Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the extension housing assembly to the J 44755  (2) using M8 x 1. See Special Tools and Equipment .25 bolts (1).

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

    8. Fig 6: Removing Flange Nut
    GM630580Courtesy of GENERAL MOTORS CORP.
  8. Install the flange nut (1) onto the driven shaft.

    Tighten:  Tighten the flange nut to 200 N.m (148 lb ft).

  9. Remove the extension housing assembly from the J 44755  . See Special Tools and Equipment .
    10. Fig 7: Measuring Rotating Torque Of Drivenshaft
    GM754966Courtesy of GENERAL MOTORS CORP.
  10. Measure the rotating torque of the driven shaft in both directions.
  11. When reusing drivenshaft bearings, the rotating torque should equal the value recorded during disassembly.

    Tighten:  A properly assembled shaft and NEW bearings should have a rotating torque of 1.5 N.m (13 lb in).

  12. Reinstall J 44755  to tighten the flange nut as required to achieve the proper rotating torque value. See Special Tools and Equipment . Do NOT loosen the flange nut to achieve the proper torque or a NEW spacer must be installed.
    13. Fig 8: Identifying Extension Housing Assembly, Shim & Bolts
    GM630584Courtesy of GENERAL MOTORS CORP.
  13. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to both sides of the shim.
  14. Align the reference marks and install the shim (2) to the transfer case.
  15. 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).

    16. Fig 9: View Of Fill & Drain Plugs
    GM630583Courtesy of GENERAL MOTORS CORP.
  16. Install the extension housing drain plug (1) and gasket to the extension housing.

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

  17. Remove the extension housing fill plug (2) and gasket.
  18. Fill the extension housing with gear oil. Refer to Transfer Case Fluid Replacement .
  19. Install the extension housing fill plug and gasket.

    Tighten:  Tighten the plug to 28 N.m (21 lb in).

    20. Fig 10: View Of Transfer Case Hose/Clamp Assembly, Vent Hose, Bracket & Bolt
    GM630581Courtesy of GENERAL MOTORS CORP.
  20. Install the vent hose (2) and clamp (1). Refer to Vent Hose Assembly Replacement (LA1)  or Vent Hose Assembly Replacement (LY7) .
  21. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  22. Lower the vehicle.
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