FixVault
Home › Pontiac › 2004 › Aztek Base, AWD › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle - 4T65-E - Overhaul › Repair Instructions › Transfer Case Installation › Installation Procedure

Installation Procedure

    Fig 1: View Of Case Extension Seal
    GM664164Courtesy of GENERAL MOTORS CORP.
  1. Install the case extension seal (8) using J 36850  in order to retain.
    2. Fig 2: Aligning Oil Passage Notch In Oil Dam
    GM630839Courtesy of GENERAL MOTORS CORP.
    NOTE: The oil dam must be installed with the oil passage notch aligned to the passage in the case. Incorrect alignment will cause oil flow stoppage and damage to the transmission.
  2. Line up the notch (1) to the hole in the case and install the oil dam (901).
    3. Fig 3: Installing Transfer Case Lower Brace Bolts
    GM630829Courtesy of GENERAL MOTORS CORP.
  3. Install the transfer case lower brace (906).
  4. Install the transfer case lower brace bolts (903). Hand tighten.
    5. Fig 4: View Of Transfer Case Assembly
    GM871800Courtesy of GENERAL MOTORS CORP.
    CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
    NOTE: The park gear thrust bearing (695) must be retained in the park gear (696) when installing the transfer case to the transmission, or damage may occur.
    IMPORTANT: When the transfer case is installed onto the transmission, there should be no gap between these parts. If a gap exists, check the park gear thrust bearing for proper retention to the park gear.
  5. Install the transfer case assembly (908) onto the transmission case (3).
    6. Fig 5: View Of Transfer Case To Case Bolts
    GM870724Courtesy of GENERAL MOTORS CORP.
  6. Install the 5 transfer case to case bolts (907, 909, 910).
    7. Fig 6: Identifying Case Bolts
    GM871808Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use air powered tools in order to assemble or disassemble transmissions. Use hand tools in order to properly determine bolt tightness. Improper bolt torque can contribute to transmission repair conditions, and this information, which is vital to diagnosis, can only be detected when using hand tools.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Torque the bolts in the following sequence:

    Tighten 2 transfer case bolts (1, 2):

    Tighten: 

    1. First pass 35 N.m (26 lb ft)
    2. Final Pass an additional 160 degrees

  8. Tighten 1 transfer case bolt (3):

    Tighten: 

    1. First pass 35 N.m (26 lb ft)
    2. Final Pass an additional 70 degrees

  9. Tighten 2 transfer case bolts (4, 5):

    Tighten:  Tighten transfer case bolts (4, 5) to 40 N.m (30 lb ft).

    10. Fig 7: Locating Transfer Case Side Brace
    GM677386Courtesy of GENERAL MOTORS CORP.
  10. Install the transfer case side brace (905) to case.
  11. Install the transfer case side brace to case bolts (903). Hand tighten the bolts.
  12. Torque the bolts in the following sequence (1, 2, 3, 4, 5).

    Tighten:  Tighten the transfer case side brace bolts to 31 N.m (23 lb ft).

    13. Fig 8: Identifying Transfer Case Lower Brace To Case Bolt
    GM630806Courtesy of GENERAL MOTORS CORP.
  13. Install the transfer case lower brace to case bolt (904).

    Tighten:  Tighten the transfer case lower brace bolt to 56 N.m (42 lb ft).

    14. Fig 9: View Of Transfer Case Lower Brace To Case Bolts
    GM659370Courtesy of GENERAL MOTORS CORP.
  14. Tighten the transfer case lower brace to case bolts (903).

    Tighten:  Tighten the transfer case lower brace bolts to 31 N.m (23 lb ft).

About FixVault