GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 OUTLOOK - FWD 🢒 Engine 🢒 Engine Controls and Fuel - 3.6L 🢒 Transfer Case Assembly Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement .
  3. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
  4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
  5. Remove the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement .
  6. Support the transaxle with a jackstand.
  7. Remove the engine rear mount bracket. Refer to Engine Rear Mount Replacement .

    8. Object Number: 2039429 Size: SH
  8. Remove the transfer case bolts (1).
  9. Remove the transfer case (2).

    10. Object Number: 2039432 Size: SH
  10. Remove the half shaft retainer (1).
  11. Remove the intermediate shaft O-ring seals (2).
  12. Remove the transfer case O-ring seal (3).

Installation Procedure

    Object Number: 2039432 Size: SH
  1. Lubricate the O-rings (2, 3) with petroleum jelly.
  2. Install the intermediate shaft O-ring seals (2).
  3. Install the half shaft retainer (1).
  4. Install the transfer case O-ring seal (3).

    5. Important: Oxidation must be removed from the transmission torque converter housing differential bore surface before installation of the transfer case. A clean bore will prevent oxidation build up from scuffing or cutting the O-ring seal upon transfer case installation, resulting in a leak.


    Object Number: 2039431 Size: SH
  5. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
  6. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
  7. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.

    8. Important: Use guide pins to aid in alignment and installation of the transfer case to the transmission. Failure to use guide pins may result in cutting the transfer case O-ring seal during installation of the transfer case causing a fluid leak.


    Object Number: 2039433 Size: SH
  8. Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
  9. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.

    10. Object Number: 2039434 Size: SH
  10. Install the transfer case (1) to the transmission.
  11. Remove the guide pins (2).

    12. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 2039435 Size: SH
  12. Install the transfer case to transmission bolts (1).

    13. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  13. Install the engine rear mount bracket. Refer to Engine Rear Mount Replacement .
  14. Remove the jackstand from under the transaxle.
  15. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement .
  16. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
  17. Install the propeller shaft. Refer to Propeller Shaft Replacement .
  18. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
  19. Lower the vehicle.