Transfer Case - AAM

• Specifications
  • Fastener Specifications
  • Approximate Fluid Capacities
  • Adhesives, Fluids, Lubricants, and Sealers
• Component Locator
  • Power Transfer Unit Case Disassembled View
    • Power Transfer Unit Components with M2D Transmission
    • Power Transfer Unit Mounting to M2D Transmission
• Diagnostic Information and Procedures
  • Symptoms - Power Transfer Unit Case
    • Strategy Based Diagnostics
    • Visual/Physical Inspection
    • Intermittent
    • Symptom List
  • Noisy in Drive
  • Noisy When Coasting
  • Intermittent Noise
  • Constant Noise
  • Power Transfer Unit Case Leak Diagnosis
• Repair Instructions - On Vehicle
  • Drain Plug Replacement
    • Removal Procedure
    • Installation Procedure
  • Fill Plug Replacement
    • Removal Procedure
    • Installation Procedure
  • Intermediate Drive Shaft Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Cover to Intermediate Drive Shaft Seal Replacement
    • Special Tools
    • Removal Procedure
    • Installation Procedure
  • Output Shaft Seal Replacement
    • Special Tools
    • Removal Procedure
    • Installation Procedure
  • Intermediate Drive Shaft Bearing Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Face Seal Replacement
    • Removal Procedure
    • Installation Procedure
  • Transfer Case Bracket Replacement
    • Removal Procedure
    • Installation Procedure
  • Transmission Brace Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Case Replacement
    • Removal Procedure
    • Installation Procedure
• Repair Instructions - Off Vehicle
  • Power Transfer Unit Case Disassemble
    • Power Transfer Unit Case Holding Fixture Installation
    • Power Transfer Unit Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal
    • Power Transfer Unit Intermediate Drive Shaft Components Removal
    • Power Transfer Unit Rear Seals Removal
    • Power Transfer Unit Extension Housing Removal
    • Power Transfer Unit Input Shaft, Idler Shaft, and Idler Shaft Tube Removal
    • Power Transfer Unit Alignment Sleeve, Face Seal, Input Shaft Bearing Race, Idler Gear Bearing Race and Shim, and Idler Gear Shaft Tube Seal Removal
    • Power Transfer Unit Idler Shaft Bearing Race, Input Shaft Bearing Race and Input Shaft Seal Removal
  • Power Transfer Unit Case Cleaning and Inspection
    • Power Transfer Unit Case Housing Cleaning and Inspection
    • Power Transfer Unit Case Extension Housing Cleaning and Inspection
    • Power Transfer Unit Input Shaft Cleaning and Inspection
    • Power Transfer Unit Idler Shaft Cleaning and Inspection
    • Power Transfer Unit Idler Shaft Tube Cleaning and Inspection
  • Power Transfer Unit Case Assemble
    • Power Transfer Unit Idler Gear Shaft Tube and O-ring, Input Shaft Bearing Race and Shim, and Idler Gear Shaft Bearing Race and Shim Installation
    • Power Transfer Unit Alignment Sleeve, Face Seal, Input Shaft Bearing Race, Idler Gear Bearing Race and Shim, and Idler Gear Shaft Tube Seal Installation
    • Power Transfer Unit Input Shaft and Idler Shaft Installation
    • Power Transfer Unit Extension Housing Installation
    • Power Transfer Unit Propeller Shaft Seal and Rear Output Shaft Seal Installation
    • Power Transfer Unit Intermediate Drive Shaft Components Installation
    • Power Transfer Unit Cover-to-Intermediate Drive Shaft Seal Installation
    • Power Transfer Unit Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation
    • Power Transfer Unit Case Holding Fixture Removal
• Description and Operation
  • Power Transfer Unit Case Identification
    • Notes
    • Transfer Case Primary Identification Label
    • Transfer Case Secondary Identification Stamping
  • Power Transfer Unit Case Description and Operation
    • General Description
    • External Components
    • Internal Components
• Special Tools and Equipment
  • Special Tools