Buick Encore: Repair instructions - on vehicle

Transfer case fluid replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Place a suitable drain pan under the transfer case.

Fig. 2: Transfer Case Drain Plugs

NOTE: Both plugs are to be discarded if removed and NEW plugs installed.

3. Remove the drain plug (2) and discard.
4. Remove the fill plug (1) and discard.

Installation Procedure

Fig. 3: Transfer Case Drain Plugs

1. Install the new drain plug.
2. Tighten the drain plug to 40 (30 lb ft).
3. Fill the transfer case to the bottom of the fill plug hole. Refer to Adhesives, Fluids, Lubricants, and Sealers
4. Install a NEW fill plug and tighten to 40 (30 lb ft).
5. Lower the vehicle.

DRAIN PLUG REPLACEMENT

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 4: Transfer Case Drain And Fill Plugs

NOTE: Both plugs are to be discarded if removed and NEW plugs installed.

2. Remove the drain plug (2) and discard.
3. Remove the fill plug (1) and discard.

Installation Procedure

Fig. 5: Transfer Case Drain And Fill Plugs

1. Install the new drain plug.
2. Tighten the drain plug to 40 (30 lb ft).
3. Fill the transfer case to the bottom of the fill plug hole.
4. Install a NEW fill plug and tighten to 40 (30 lb ft).
5. Lower the vehicle.

FILL PLUG REPLACEMENT

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 6: Transfer Case Drain And Fill Plugs

2. Remove the fill plug (1) and discard.

Installation Procedure

Fig. 7: Transfer Case Drain And Fill Plugs

1. Install a NEW fill plug.
2. Tighten the fill plug to 40 (30 lb ft).
3. Lower the vehicle.

TRANSFER CASE VENT HOSE REPLACEMENT

Removal Procedure

Fig. 8: Vent Hose And Retaining Clip

1. Unclip the upper portion of the vent hose (2) from the retaining clip (1).
2. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .

Fig. 9: Transfer Case Vent Hose

3. Disconnect the vent hose (1) from the transfer case (2).
4. Remove the vent hose from the vehicle.

Installation Procedure

Fig. 10: Transfer Case Vent Hose

1. Connect the vent hose (1) to the transfer case (2).
2. Lower the vehicle.

Fig. 11: Vent Hose And Retaining Clip

3. Clip the upper portion of the vent hose (2) to the retaining clip (1).

Front wheel drive intermediate shaft replacement

Special Tools

• J-41819 Input Shaft Seal Installer
• DT-50937 Seal Protector

For equivalent regional tools, refer to Special Tools.

Removal Procedure

1. Remove the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

Fig. 12: Front Wheel Drive Intermediate Shaft Housing Fasteners

2. Remove the front wheel drive intermediate shaft housing fasteners (1).

Fig. 13: Front Wheel Drive Intermediate Shaft Assembly

3. Remove the front wheel drive intermediate shaft assembly (1).
4. Inspect the bearing (1) and shaft (2) for wear or damage, if replacement is necessary, refer to Front Wheel Drive Intermediate shaft component disassembly in Transfer Case Disassemble, and Transfer Case Assemble for assembly.

Fig. 14: Front Wheel Drive Intermediate Shaft Seal

5. Remove and DISCARD the front wheel drive intermediate shaft seal (1).

Installation Procedure

Fig. 15: Front Wheel Drive Intermediate Shaft Seal And Installer

1. Using J-41819 Input Shaft Seal Installer install the NEW front wheel drive intermediate shaft seal (1).

Fig. 16: Front Wheel Drive Intermediate Shaft Assembly

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

Refer to Transfer Case Description and Operation - New Service Assembly for additional information.

2. Using DT-50937 Seal Protector install the front wheel drive intermediate shaft assembly (1).

Fig. 17: Front Wheel Drive Intermediate Shaft Housing Fasteners

CAUTION: Refer to Fastener Caution .

3. Install the front wheel drive intermediate shaft housing fasteners (1) and tighten to 58 (43 lb ft).
4. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .

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.

Transfer case adapter replacement

Removal Procedure

1. Remove the transfer case. Refer to Transfer Case Replacement.

Fig. 24: Transfer Case-To-Transfer Case Bracket Seal

2. Remove and DISCARD the transfer case adapter seal from the transmission adapter.

Fig. 25: Transmission Adapter Bolts

3. Remove and DISCARD the five transmission adapter fasteners (1).

Fig. 26: Transmission Bracket And Through Bolt

4. Remove and DISCARD the rear transmission mount through bolt (1).
5. Remove the transmission adapter (2) from the transmission.

Installation Procedure

Fig. 27: Transmission Bracket And Through Bolt

1. Install the transmission adapter (2) to the transmission.

Fig. 28: Transmission Adapter Bolts

CAUTION: Refer to Fastener Caution .

2. For manual transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.

Fig. 29: Transmission Bracket Fasteners

3. For automatic transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
4. Install the NEW transmission adapter to transmission fastener (2) and tighten to 60 N.m (44 lb ft) plus 60- 75 degrees.

Fig. 30: Transmission Bracket And Through Bolt

5. Install the NEW rear transmission mount through bolt (1) and tighten to 80 N.m (59 lb ft) plus 45-60 degrees.

Fig. 31: Transfer Case-To-Transfer Case Bracket Seal

6. Install the NEW transfer case adapter seal from the transmission adapter.
7. Install the transfer case. Refer to Transfer Case Replacement.

TRANSFER CASE ADAPTER BUSHING REPLACEMENT

Removal Procedure

1. Remove the transfer case. Refer to Transfer Case Replacement.

Fig. 32: Transfer Case-To-Transfer Case Bracket Seal

2. Remove and DISCARD the transfer case adapter seal from the transmission adapter.

Fig. 33: Transmission Adapter Bolts

3. Remove and DISCARD the five transmission adapter fasteners (1).

Fig. 34: Transmission Bracket And Through Bolt

4. Remove and DISCARD the rear transmission mount through bolt (1).
5. Remove the transmission adapter (2) from the transmission.
6. Inspect the rear mount bushing the transmission adapter for wear or damage. Refer to Transfer Case Adapter Disassemble (MHB), Transfer Case Adapter Disassemble (M7Y, MZ4).

Installation Procedure

1. Install the rear mount bushing to the transmission adapter. Refer to Transfer Case Adapter Assemble (MHB), Transfer Case Adapter Assemble (M7Y, MZ4).

Fig. 35: Transmission Bracket And Through Bolt

2. Install the transmission adapter (2) to the transmission.

Fig. 36: Transmission Adapter Bolts

CAUTION: Refer to Fastener Caution .

3. For manual transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.

Fig. 37: Transmission Bracket Fasteners

4. For automatic transmission, install the NEW transmission adapter to transmission fasteners (1) and tighten to 100 N.m (74 lb ft) plus 30-40 degrees.
5. Install the NEW transmission adapter to transmission fastener (2) and tighten to 60 N.m (44 lb ft) plus 60- 75 degrees.

Fig. 38: Transmission Bracket And Through Bolt

6. Install the NEW rear transmission mount through bolt (1) and tighten to 80 N.m (59 lb ft) plus 45-60 degrees.

Fig. 39: Transfer Case-To-Transfer Case Bracket Seal

7. Install the NEW transfer case adapter seal from the transmission adapter.
8. Install the transfer case. Refer to Transfer Case Replacement.

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