Buick Regal: Power Transfer Unit Cover To Intermediate Drive Shaft Seal Replacement

Special Tools

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

Equivalent regional tools: Special Tools

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle.

NOTE: The drive shaft remains in the wheel hub.

2. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Disconnect.

3. Transfer Case Bracket - Remove.

4.

Retaining Ring(1) - Remove and DISCARD.

5. O-Ring(2) - Remove and DISCARD.

6.

NOTE: Use a flat-bladed tool (2) to remove the seal from the housing. Avoid damage to the housing seal bore or shaft sealing surface.

Power Transfer Unit Cover to Intermediate Drive Shaft Seal(1) - Remove and DISCARD.

Installation Procedure

1.

Power Transfer Unit Cover to Intermediate Drive Shaft Seal(1) - Install NEW - Use the special tool: DT- 51466 installer (2) & DT-305-1 handle (3).

2.

O-Ring(2) - Install NEW.

3. Retaining Ring(1) - Install NEW.

4. Transfer Case Bracket - Install.

5. Front Wheel Drive Half Shaft- Right Side@Transfer Case - Connect.

6. Lower the vehicle.

OUTPUT SHAFT SEAL REPLACEMENT

Special Tools

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

Equivalent regional tools:Special Tools

Removal Procedure

1. Remove the drain plug and drain the transfer unit.

2. Remove the propeller shaft.

3.

Remove and DISCARD the propeller shaft retainer (1).

4. Remove and DISCARD the propeller shaft O-ring (2).

NOTE: Use a suitable flat bladed tool 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.

5. Remove and DISCARD the transfer unit output seal (3).

Installation Procedure

1.

Using DT-51467 Seal Installer (1) and DT-305 - 1 Driver Handle (2) install the NEW transfer unit output seal.

2.

Install the NEW transfer unit propeller shaft O-ring (2).

3. Install the NEW transfer unit propeller shaft retainer (1).

4. Install the propeller shaft.

5. fill the transfer unit to the bottom of the fill plug hole with the recommended fluid.

INTERMEDIATE DRIVE SHAFT BEARING REPLACEMENT

Removal Procedure

1. Intermediate Drive Shaft Replacement - Remove.

2.

Using a press, remove the intermediate drive shaft bearing (2) from the intermediate drive shaft. Refer to power transfer unit intermediate drive shaft in Power Transfer Unit Case Disassemble.

Installation Procedure

1.

Using a press, install the intermediate drive shaft bearing (2) to the intermediate drive shaft. Refer to power transfer unit intermediate drive shaft in Power Transfer Unit Case Assemble.

2. Intermediate Drive Shaft Replacement - Install.

POWER TRANSFER UNIT FACE SEAL REPLACEMENT

Removal Procedure

1. Remove the power transfer unit from the vehicle.

2.

Remove and DISCARD the power transfer unit face seal (1) from the power transfer unit.

Installation Procedure

1.

Install the NEW power transfer unit face seal (1) to the power transfer unit.

2. Install the transfer case in the vehicle.

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