Chevrolet Trax: Rear output shaft seal 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 rear propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
4. Remove the rear output shaft housing. Refer to Transfer Case Rear Output Shaft Housing Removal in Transfer Case Disassemble.
5. Remove the transfer case rear output shaft flange. Refer to Transfer Case Propeller Shaft Flange Removal in Transfer Case Disassemble.
6. Remove the transfer case rear output shaft seal. Refer to Transfer Case Rear Output Shaft Removal in Transfer Case Disassemble.

Installation Procedure

1. Install the transfer case rear output shaft seal. Refer to Transfer Case Rear Output Shaft Installation in Transfer Case Assemble.
2. Install the transfer case propeller shaft flange. Refer to Transfer Case Propeller Shaft Flange in Transfer Case Assemble.
3. Install the rear output shaft housing. Refer to Transfer Case Rear Output Shaft Housing Installation in Transfer Case Assemble.
4. Install the rear propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
5. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement.
6. Lower the vehicle.

TRANSFER CASE REPLACEMENT

Removal Procedure

Fig. 18: Transfer Case Vent Hose

1. Disconnect the transfer case vent hose (1) from the transfer case.
2. Drain the fluid from the transmission. Refer to Transmission Fluid Drain and Fill .
3. Remove the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

NOTE: The intermediate drive shaft is to be removed from the transfer case assembly prior to the transfer case assembly being removed from the vehicle. Prior to removal of the shaft from the assembly, seal protector DT- 50937 must be installed to protect the front wheel drive intermediate shaft seal.

4. Remove the intermediate drive shaft from the transfer case. Refer to Front Wheel Drive Intermediate Shaft Replacement.
5. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
6. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
7. Support the transfer case (2) with a suitable jack, and secure with suitable straps.

Fig. 19: Transfer Case Bolts

8. Remove and DISCARD the four transfer case fasteners (1).
9. Separate the transfer case (2) from the transmission and remove the transfer case.

Fig. 20: Transfer Case-To-Transfer Case Bracket Seal

10. Remove and discard the transfer case-to-transfer case bracket seal (1).

Installation Procedure

Fig. 21: Transfer Case-To-Transfer Case Bracket Seal

1. Clean the contact surfaces between the transfer case and the transfer case bracket.
2. Install a new transfer case-to-transfer case bracket seal (1).
3. Support the transfer case with a suitable jack, and secure with suitable straps.
4. Raise and align the transfer case in the correct position in relation to the transmission

Fig. 22: Transfer Case Bolts

5. Install the transfer case (2) to the transfer case bracket.

CAUTION: Refer to Fastener Caution .

6. Install the NEW transfer case-to-transfer case bracket fasteners (1) and tighten to 100 (74 lb ft) plus 30-45 degrees.

NOTE: The intermediate drive shaft is to be installed into the transfer case assembly after the transfer case assembly is installed into the vehicle.

Prior to installation of the shaft into the assembly, seal protector DT-50937 must be installed to protect the front wheel drive intermediate shaft seal.

7. Install the intermediate drive shaft into the transfer case. Refer to Front Wheel Drive Intermediate Shaft Replacement.
8. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
9. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .

Fig. 23: Transfer Case Vent Hose

10. Connect the transfer case vent hose (1) to the transfer case.
11. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
12. Fill the transmission with fluid. Refer to Transmission Fluid Drain and Fill .
13. Check the transfer case fluid. Refer to Approximate Fluid Capacities.

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