Buick Regal: 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

1. Power Transfer Unit Idler Gear Shaft Access Tube O-ring- Rear
2. Power Transfer Unit Idler Shaft Tube

Procedure

The tube orientation for assembly. Install the tube with the knurled OD area facing the extension housing.

3. Power Transfer Unit Idler Gear Shaft Bearing Race Shim- Rear

NOTE: The position of the shim for assembly.

4. Power Transfer Unit Idler Gear Shaft Bearing Race- Rear

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

5. Power Transfer Unit Input Shaft Seal- Rear

Procedure

1. Make sure the seal bore is clean and free of oil or dirt.
2. Install the NEW seal with the notched surface of the seal facing the installer tool.
3. Install the seal onto the DT-51466 Seal Installer with the metal ID portion of the seal facing the DT-51466 Seal Installer.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

6. Power Transfer Unit Input Shaft Bearing Race Shim- Rear

NOTE: The position of the shim for assembly.

7. Power Transfer Unit Input Shaft Bearing Race- Rear

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

Power Transfer Unit Alignment Sleeve, Face Seal, Input Shaft Bearing Race, Idler Gear Bearing Race and Shim, and Idler Gear Shaft Tube Seal Installation

1. Power Transfer Unit Alignment Sleeve

Procedure

1. Install a NEW sleeve during assembly.
2. Use a press to install the sleeve. Install the sleeve with the tapered end facing away from case. Press the sleeve into the housing until it bottoms in the case half bore.

2. Power Transfer Unit Face Seal
3. Power Transfer Unit Input Shaft Seal- Front

Procedure

1. Make sure the seal bore is clean and free of oil or dirt.
2. Install the NEW seal with the notched surface of the seal facing the installer tool.
3. Install the seal onto the DT-51466 Seal Installer with the metal ID portion of the seal facing the DT-51466 Seal Installer.
4. Install the seal into the bore until the tool bottoms against the case half.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

4. Power Transfer Unit Input Shaft Bearing Race- Front

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

5. Power Transfer Unit Idler Gear Shaft Tube O-ring- Front
6. Power Transfer Unit Idler Gear Shaft Bearing Race Shim- Front

NOTE: The position of the shim for assembly.

7. Power Transfer Unit Idler Gear Shaft Bearing Race- Front

Procedure

1. The bearing races are not an interference fit to the housing bore.
2. Apply a thin coating of assembly grease to the OD of the race to retain it in the housing.

8. Power Transfer Unit Locating Pin [2x]

NOTE: Install the locating pins as required.

Power Transfer Unit Input Shaft and Idler Shaft Installation

1. Power Transfer Unit Idler Shaft
2. Power Transfer Unit Input Shaft

Power Transfer Unit Extension Housing Installation

Fig. 1: Power Transfer Unit Extension Housing Installation Tightening Sequence

1. Power Transfer Unit Cover Housing Seal

Procedure

1. Do NOT reuse the housing seal. Install a NEW seal during assembly.
2. Inspect the extension housing and main housing seal surfaces to ensure they are clean and free of damage prior to assembly.

2. Power Transfer Unit Cover Housing
3. Power Transfer Unit Cover Housing Bolt [10x]

CAUTION: Refer to Fastener Caution.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

Procedure

1. Clean the internal threads (no residual pre-applied adhesive allowed)
2. Use NEW bolts without pre-applied adhesive
3. Apply threadlocker to the threads of the NEW bolts.

Tighten in sequence

1. First Pass: 28 N.m (21 lb ft)
2. Final Pass:90 degrees

Power Transfer Unit Propeller Shaft Seal and Rear Output Shaft Seal Installation

1. Power Transfer Unit Output Shaft Seal

Procedure

1. Install a NEW seal.
2. Make sure the seal bore is clean and free of oil or dirt.

Special Tools

• DT-51467 - A Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

2. Power Transfer Unit Propeller Shaft Seal

NOTE: Install a NEW seal.

3. Power Transfer Unit Propeller Shaft Retainer

Procedure

1. Install a NEW retainer.
2. When installing a NEW half shaft retaining clip, open the clip only as far as necessary to fit the clip over the shaft. Opening the clip too far will damage it.
3. Start one end of the clip in the shaft groove and slowly push the clip onto and over the shaft.

Power Transfer Unit Intermediate Drive Shaft Components Installation

1. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

2. Power Transfer Unit Intermediate Drive Shaft Bearing

Procedure

Use a press to install the bearing to the shaft.

3. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

CAUTION: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

4. Power Transfer Unit Intermediate Drive Shaft
5. Power Transfer Unit Intermediate Drive Shaft Retainer

Power Transfer Unit Cover-to-Intermediate Drive Shaft Seal Installation

1. Power Transfer Unit Cover to Intermediate Drive Shaft Seal

Procedure

1. Install a NEW seal.
2. Lubricate the OD area of the seal with a light film of grease or oil prior to installation.

Special Tools

• DT-51466 Seal Installer
• DT-305 - 1 Driver Handle

Equivalent regional tools: Special Tools

2. Power Transfer Unit Half Shaft Seal

Procedure

Do NOT reuse the O-ring. Install a NEW O-ring seal.

3. Power Transfer Unit Half Shaft Retainer Clip

CAUTION: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.

Procedure

Do NOT reuse the intermediate shaft retaining clip. Install a NEW clip.

Power Transfer Unit Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation

1. Power Transfer Unit Drain Plug

Procedure

The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

Tighten 40 N.m (30 lb ft)

2. Power Transfer Unit Fill Plug

Procedure

1. The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.
2. Tighten the oil fill plug only after the assembly has been filled with fluid.

Tighten 40 N.m (30 lb ft)

3. Power Transfer Unit Vent Hose Connector

Procedure

Apply sealant to the threads of the connector.

Tighten 20 N.m (15 lb ft)

Power Transfer Unit Heat Shield Removal

1. Power Transfer Unit Heat Shield
2. Power Transfer Unit Heat Shield Bolt [3x]

Tighten 12 N.m (106 lb in)

Power Transfer Unit Case Holding Fixture Removal

1. Power Transfer Unit Case

Special Tools

• DT-3289-20 Holding Fixture
• DT-36842 Transaxle Holding Fixture

Equivalent regional tools: Special Tools

READ NEXT: