Buick Regal: Power Transfer Unit Case Cleaning and Inspection

Power Transfer Unit Case Housing Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit case housing.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the power transfer unit must be replaced as an assembly.

1. Power Transfer Unit Case Housing Threaded Bolt Holes

NOTE: Repair any damaged threads.

2. Power Transfer Unit Case Housing Sealing Surfaces

NOTE: Repair small scratches or nicks with a soft stone.

3. Power Transfer Unit Input Shaft Seal Surface

NOTE: Inspect for thread damage or sealing surface.

4. Power Transfer Unit Idler Shaft Tube Seal Surface

NOTE: Inspect for thread damage or sealing surface.

5. Power Transfer Unit Drain Plug Hole

NOTE: Inspect for thread damage or sealing surface.

6. Power Transfer Unit Rear Output Shaft and Splines

Procedure

Rotate the shaft by hand. The shaft should rotate freely with no roughness felt within the bearings. If roughness within bearings is present, replace the power transfer unit as an assembly.

NOTE:

• Inspect the rear output shaft for end play. If end play is present, replace the power transfer unit as an assembly.
• Inspect the splines for damage or excessive wear.

Power Transfer Unit Case Extension Housing Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit extension housing in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.

1. Power Transfer Unit Case Extension Housing

NOTE: Inspect for excessive wear, cracks, or damage. The power transfer unit case assembly must be replaced if damage is present.

2. Power Transfer Unit Case Extension Housing Sealing Surfaces

NOTE: Repair small scratches or nicks with a soft stone.

3. Idler Gear Shaft Tube O-ring Sealing Surface
4. Power Transfer Unit Case Fill Plug Hole

NOTE: Inspect for thread damage or sealing surface.

Power Transfer Unit Input Shaft Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit input shaft in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the power transfer unit must be replaced as an assembly

1. Power Transfer Unit Input Shaft Splines

NOTE: Inspect for excessive wear, cracks, or damage.

2. Power Transfer Unit Input Shaft - Front Seal Surface

NOTE: Inspect for pitting, excessive wear, or damage.

3. Power Transfer Unit Input Shaft Gear Teeth

NOTE: Inspect for excessive wear or damage.

4. Power Transfer Unit Input Shaft - Intermediate Drive Shaft Seal Surface

NOTE: Inspect for pitting, excessive wear, or damage.

5. Power Transfer Unit Input Shaft Bearing - Rear

NOTE: Inspect for excessive wear or damage.

6. Power Transfer Unit Input Shaft Bearing - Front

NOTE: Inspect for excessive wear or damage.

Power Transfer Unit Idler Shaft Cleaning and Inspection

Preliminary Procedure

• Clean the power transfer unit idler shaft in cleaning solvent and air dry.
• The case halves, internal gears and bearings are not serviceable components. If damage is present, the transfer case assembly must be replaced.

1. Power Transfer Unit Idler Shaft Bearing - Front

NOTE: Inspect for excessive wear or damage.

2. Power Transfer Unit Idler Shaft Gear Teeth

NOTE: Inspect for excessive wear or damage.

3. Power Transfer Unit Idler Shaft Bearing - Rear

NOTE: Inspect for excessive wear or damage.

Power Transfer Unit Idler Shaft Tube Cleaning and Inspection

Preliminary Procedure

Clean the power transfer unit idler shaft tube in cleaning solvent and air dry.

1. Power Transfer Unit Idler Shaft Tube O-ring (Front)
2. Power Transfer Unit Idler Shaft Tube

NOTE: Inspect for excessive wear or damage.

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

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