Rendezvous 2006-2007

Transfer Case Removal & Installation

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3.4L & 3.5L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Propeller shaft
     
    Gear oil from the extension housing
     
    Transmission fluid from the case
     
    Speed sensor electrical connector
     
    Transfer case lower brace bolts and brace
     
    Clamp from the extension housing vent hose coupling
     
    Vent hose bracket-to-transfer case bolt
     
    Vent hose coupling, vent hose and bracket
     
    Transaxle
     
    Output shaft retaining ring
     

  4.  
  5. Rotate the transaxle 90 degrees.

    Transfer case lower brace bolt
     

  6.  
  7. Rotate the transfer case 90 degrees back to the installed position
    CAUTION
    The transfer case weighs about 60 pounds. Be sure to lift the case properly, to avoid injury.



    Transfer case side brace bolts and side brace
     
    Transfer case-to-transaxle bolts
     



    Transfer case from the transaxle. Note that the output shaft withdraws from the transaxle with the transfer case.
     
    Output shaft
     
    Transfer case O-ring from the transfer case

    Click image to see an enlarged view

    Fig. Transfer case (1), output shaft (2) and transaxle (3)-3.4L and 3.5L Engines

     

  8.  

To install:

  1. Install or connect the following:

    O-ring seal to the transfer case
     

  2.  
  3. Rotate the transaxle so the bottom pan is facing the floor.

    Transfer case to the transaxle
     

  4.  
  5. Torque the transfer case bolts, in sequence, as follows:
    1. Bolts 1 and 2: 26 ft. lbs. (35 Nm), plus an additional 160 degrees.
    2.  
    3. Bolt 3: 26 ft. lbs. (35 Nm), plus an additional 70 degrees.
    4.  
    5. Bolts 4 and 5: 30 ft. lbs. (40 Nm).

      Click image to see an enlarged view

      Fig. Transfer case bolt tightening sequence-3.4L and 3.5L Engines



      Transfer case side brace. Tighten the bolts, in sequence, to 35 ft. lbs. (47 Nm).

      Click image to see an enlarged view

      Fig. Transfer case side brace bolt tightening sequence-3.4L and 3.5L Engines

       

    6.  

  6.  
  7. Rotate the transaxle 90 degrees.

    Transfer case lower brace-to-transaxle bolt. Torque the bolt to 35 ft. lbs. (47 Nm).
     
    Output shaft
     
    New output shaft retaining ring
     
    Transaxle
     
    Vent hose and coupling to the extension housing. Secure with the clamp.
     
    Vent hose bracket and bolt/stud. Tighten to 106 inch lbs. (10 Nm).
     
    Speed sensor electrical connector
     
    Propeller shaft
     
    Transfer case lower brace. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    Drain plugs and gaskets to the transfer case and extension housing. Torque the plugs to 24 ft. lbs. (32 Nm).
     

  8.  
  9. Check the transaxle fluid level.
  10.  
  11. Remove the extension housing fill plug and fill the housing with suitable gear oil. Install the plug and tighten to 24 ft. lbs. (32 Nm).
  12.  

3.6L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

  2.  
  3. Remove the drive shaft retaining ring.
  4.  
  5. Rotate the transaxle 90 degrees.
  6.  
  7. Remove the transfer case lower brace bolt.
  8.  
  9. Rotate the transaxle 90 degrees.
  10.  
  11. Remove the transfer case side brace bolts. Remove the side brace.
  12.  
  13. Remove the transfer case to case bolts.
    CAUTION
    This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.


    NOTE
    During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.

  14.  
  15. Remove the transfer case assembly from the transmission case.
  16.  
  17. Remove the transfer case lower brace bolts.
  18.  
  19. Remove the transfer case lower brace.
  20.  
  21. Remove the case extension seal from the transfer case.
  22.  
  23. Position the transaxle so that the case side cover is facing down.
  24.  
  25. Remove the oil dam from the transaxle.
  26.  
  27. Install the transfer case assembly onto a work stand.
  28.  

To install:

  1. Install the case extension seal.
    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.  
  3. Line up the notch to the hole in the case and install the oil dam.
  4.  
  5. Install the transfer case lower brace.
  6.  
  7. Install the transfer case lower brace bolts. Hand tighten.
    NOTE
    The park gear thrust bearing must be retained in the park gear when installing the transfer case to the transmission, or damage may occur.


    NOTE
    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.

  8.  
  9. Install the transfer case assembly onto the transmission case.
  10.  
  11. Install the 5 transfer case to case bolts.
    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
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



    Click image to see an enlarged view

    Fig. Transfer case bolt torque sequence-with 3.6L engine

  12.  
  13. Torque the bolts in the following sequence:

    Tighten 2 transfer case bolts (1, 2): First pass 26 ft. lbs. (35 Nm). Final Pass an additional 160 degrees
     
    Tighten 1 transfer case bolt (3): First pass 26 ft. lbs. (35 Nm). Final Pass an additional 70 degrees
     
    Tighten 2 transfer case bolts (4, 5): Tighten transfer case bolts (4, 5) to 30 ft. lbs. (40 Nm).
     

  14.  
  15. Install the transfer case side brace to case.
  16.  
  17. Install the transfer case side brace to case bolts. Hand tighten the bolts.

    Click image to see an enlarged view

    Fig. Transfer case side bolt torque sequence-with 3.6L engine

  18.  
  19. Torque the bolts in the following sequence (1, 2, 3, 4, 5). Tighten the transfer case side brace bolts to 23 ft. lbs. (31 Nm).
  20.  
  21. Install the transfer case lower brace to case bolt. Tighten the transfer case lower brace bolt to 42 ft. lbs. (56 Nm).
  22.  
  23. Tighten the transfer case lower brace to case bolts. Tighten the transfer case lower brace bolts to 23 ft. lbs. (31 Nm).
  24.  

 
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