Buick Regal: Power Transfer Unit Case Disassemble

Power Transfer Unit Case Holding Fixture Installation

1. Power Transfer Unit Case

Procedure

Always secure with the pivot pin after rotating.

NOTE: The power transfer unit can be rotated 360 degrees to facilitate repair.

Special Tools

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

Equivalent regional tools: Special Tools

Power Transfer Unit Heat Shield Removal

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

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

1. Power Transfer Unit Oil Fill Plug

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

2. Power Transfer Unit Oil Drain Plug

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

3. Power Transfer Unit Vent Hose Connector

NOTE: Remove the vent hose connector only if replacement is required.

Power Transfer Unit Intermediate Drive Shaft Components Removal

1. Power Transfer Unit Half Shaft Retainer

Procedure

Remove and DISCARD the retainer.

2. Power Transfer Unit Half Shaft Seal (O-ring)

Procedure

Remove and DISCARD the O-ring seal.

3. Power Transfer Unit Cover-to-Intermediate Drive Shaft Seal

NOTE: Push the OD flange of the seal to remove from extension housing and shaft.

4. Power Transfer Unit Intermediate Drive Shaft Retainer
5. Power Transfer Unit Intermediate Drive Shaft
6. 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.

7. Power Transfer Unit Intermediate Drive Shaft Bearing

Procedure

Use a press to remove the bearing from the power transfer unit intermediate drive shaft.

8. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring

Power Transfer Unit Rear Seals Removal

1. Power Transfer Unit Propeller Shaft Retainer

Procedure

Remove and DISCARD the retainer.

2. Power Transfer Unit Propeller Shaft Seal (O-ring)
3. Power Transfer Unit Rear Output Shaft Seal

Procedure

1. Use a screwdriver to remove the seal from the housing. Remove the inner part of the seal first and then the outer part of the seal. Use care to prevent damage to the housing seal bore or shaft sealing surface. The seal is to be removed in two pieces.
2. Remove and DISCARD the seal.

Power Transfer Unit Extension Housing Removal

1. Power Transfer Unit Cover Extension Housing Bolt [10x]

Procedure

Remove and DISCARD the cover extension housing bolts. Install NEW rear extension housing bolts during assembly.

2. Power Transfer Unit Extension Housing
3. Power Transfer Unit Cover Housing Seal

Procedure

Remove and DISCARD the seal.

Power Transfer Unit Input Shaft, Idler Shaft, and Idler Shaft Tube Removal

1. Power Transfer Unit Input Shaft Assembly
2. Power Transfer Unit Idler Shaft Assembly
3. Power Transfer Unit Idler Shaft Tube

NOTE: The orientation of the tube for assembly. The end of the tube with the knurled OD area is to be facing the extension housing.

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

1. Power Transfer Unit Input Shaft Bearing Race - Front

NOTE: The bearing races are not an interference fit to the housing bore.

2. Power Transfer Unit Input Shaft Seal - Front

Procedure

Remove and DISCARD the seal.

Special Tools

• DT-26941 Bushing and Bearing Remover
• DT-45124 Removal Bridge

Equivalent regional tools: Special Tools

3. Power Transfer Unit Idler Gear Bearing Race - Front

NOTE: The bearing races are not an interference fit to the housing bore.

4. Power Transfer Unit Idler Gear Bearing Race Shim - Front

NOTE: The position of the shim for assembly.

5. Power Transfer Unit Idler Gear Shaft Tube O-ring - Front
6. Power Transfer Unit Locating Pins, as required [2x]
7. Power Transfer Unit Alignment Sleeve

Procedure

Discard the alignment sleeve if removed. Install a NEW sleeve during assembly.

Special Tools

• DT-44380 Differential Bearing Puller
• DT-45124 Removal Bridge
• DT-45124 - 9 Puller Legs

Equivalent regional tools: Special Tools

8. Power Transfer Unit Face Seal

Procedure

Remove and DISCARD the seal.

Power Transfer Unit Idler Shaft Bearing Race, Input Shaft Bearing Race and Input Shaft Seal Removal

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

NOTE: The bearing race is not an interference fit to the housing bore.

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

NOTE: The position of the shim for assembly.

3. Power Transfer Unit Idler Gear Shaft Tube O-ring - Rear

Procedure

Remove and DISCARD the seal.

4. Power Transfer Unit Input Shaft Bearing Race - Rear

NOTE: The bearing race is not an interference fit to the housing bore.

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

NOTE: The position of the shim for assembly.

6. Power Transfer Unit Input Shaft Seal - Rear

Special Tools

• DT-26941 Bushing and Bearing Remover
• DT-45124 Removal Bridge

Equivalent regional tools: Special Tools

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