2003 Pontiac Aztek AWDFACTORY OEM SERVICE PROCEDURE

Transfer Case - STEYR (Unit Repair): Specifications

Fastener Tightening Specifications

Application Specification
Metric English
Case-Le ft Drain Plug 32 N.m 24 lb ft
Case M10 Bolts 60 N.m 44 lb ft
Case M8 Bolts 32 N.m 23 lb ft
Differential Carrier Nut 500 N.m 369 lb ft
Extension Housing Bolts 32 N.m 23 lb ft
Extension Housing Drain Plug 32 N.m 23 lb ft
Extension Housing Fill Plug 28 N.m 21 lb ft
Flange Nut 250 N.m 185 lb ft
Holding Fixture J 44755  M10 Bolts 50 N.m 37 lb ft
Holding Fixture J 44755  M8 Bolts 25 N.m 18 lb ft
Output Driveshaft Housing M10 Bolts 60 N.m 44 lb ft
Output Driveshaft Housing M8 Bolts 32 N.m 23 lb ft
Output Driveshaft Nut 505 N.m 372 lb ft
Speed Sensor Bolt 30 N.m 22 lb ft
Transfer Case-to-Transaxle Bolts - in sequence 50 N.m 37 lb ft
Transfer Case-to-Transaxle M10 Brace Bolts 56 N.m 41 lb ft
Transfer Case-to-Transaxle M8 Brace Bolts 32 N.m 23 lb ft
General Specifications

Application Specification
Metric English
Differential Bearing Preload 0.1-0.15 mm 0.004-0.006 in
Differential Carrier Rotating Torque 1.5 N.m 13 lb in
Drive and Driven Shafts Gears Backlash 0.2-0.3 mm 0.0078-0.0118 in
Drivenshaft Rotating Torque 1.5 N.m 13 lb in
Driveshaft Bearing Preload 0.15 mm 0.006 in
Driveshaft Rotating Torque 1.5 N.m 13 lb in
Extension Housing Gear Oil Fill Quantity 290 ml 9.80 oz
Gear Ratio Front-to-Rear 1.013:1
Idler Gear Bearing Preload 1.02-1.78 mm 0.004-0.007 in
Fig 1: Extension Housing Shim Calculation (1 Of 2)
G01365522Courtesy of GENERAL MOTORS CORP.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.