Power Transfer Unit Case Disassemble

Special Tools

• DT-3289-20  Holding Fixture
• DT-26941  Bushing and Bearing Remover
• DT-36842  Transaxle Holding Fixture
• DT-45124  Removal Bridge

Equivalent regional tools: Special Tools 

1. Courtesy of GENERAL MOTORS COMPANY

   NOTE:

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

   Power Transfer Unit Case (4) Install @ DT-36842  Transaxle Holding Fixture (3)

2. Always secure with the pivot pin (1) after rotating DT-36842  Transaxle Holding Fixture in DT-3289-20  Holding Fixture.

3. Courtesy of GENERAL MOTORS COMPANY

   Power Transfer Unit Heat Shield Bolt (1) - Remove [3x]

4. Power Transfer Unit Heat Shield (2) - Remove

5. Courtesy of GENERAL MOTORS COMPANY

   NOTE:

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

   Power Transfer Unit Drain Plug (1) - Remove and DISCARD

6. Power Transfer Unit Fill Plug (3) - Remove and DISCARD
NOTE:

Remove the vent hose connector only if replacement is required.

7. Power Transfer Unit Vent Hose Connector (2) - Remove

8. Courtesy of GENERAL MOTORS COMPANY

   Power Transfer Unit Propeller Shaft Retainer (1) - Remove and DISCARD

9. Power Transfer Unit Propeller Shaft Seal O-Ring (2) - Remove and DISCARD
10. 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.
11. Power Transfer Unit Propeller Shaft Seal (3) - Remove and DISCARD

12. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Half Shaft Retainer Clip (1) - Remove and DISCARD

13. Power Transfer Unit Propeller Shaft Seal (2) - Remove and DISCARD
NOTE:

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

14. Power Transfer Unit Cover to Intermediate Drive Shaft Seal (3) - Remove and DISCARD
15. Power Transfer Unit Intermediate Drive Shaft Clip (4) - Remove

16. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Cover Housing Bolt (1) - Remove [2x]

17. Power Transfer Unit Intermediate Drive Shaft Bearing Housing (2) - Remove
18. Power Transfer Unit Intermediate Drive Shaft Housing Seal (3) - Remove and DISCARD

19. Courtesy of GENERAL MOTORS COMPANY

    NOTE:

    Remove as an assembly and replace bearing as needed.

    Power Transfer Unit Intermediate Drive Shaft (3) - Remove

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

21. Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring (1) - Remove [2x]
22. Power Transfer Unit Intermediate Drive Shaft Bearing (2) - Remove

23. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Shift Actuator Bolt (1) - Remove [2x]

24. Power Transfer Unit Shift Actuator Bolt (2) - Remove [2x]
25. Power Transfer Unit Shift Actuator (3) - Remove
26. Power Transfer Unit Shift Actuator Seal (4) - Remove and DISCARD

27. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Extension Housing Bolt (1) - Remove and DISCARD [8x]

28. Power Transfer Unit Extension Housing (2) - Remove
29. Power Transfer Unit Cover Housing Seal (3) - Remove and DISCARD

30. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Shift Actuator Locker (1) - Remove

31. Power Transfer Unit Shift Actuator Gear (2) - Remove
32. Power Transfer Unit Shift Actuator Shaft (3) - Remove
33. Power Transfer Unit Pinion Compression Sleeve (4) - Remove

34. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Input Shaft Assembly

    (1) - Remove

35. Courtesy of GENERAL MOTORS COMPANY

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

36. Power Transfer Unit Input Shaft Seal- Rear (1) - Remove and DISCARD

37. Courtesy of GENERAL MOTORS COMPANY

    Power Transfer Unit Face Seal (1) - Remove and DISCARD

38. DT-26941  Bushing and Bearing Remover and DT-45124  Removal Bridge - Install
39. Power Transfer Unit Input Shaft Seal- Front (2) - Remove and DISCARD