Service Manual2007 Captiva TRANSFER CASE

SECTION 5D

TRANSFER CASE

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

General Specificaitons

Application	Specification
Lubricant Type	Synthetic Hypoid 75W-90
Lubricant Capacity (Transfer case fill)	0.8 ± 0.1L (0.85 ± 0.1 qt)
Gear Ratio	2.535 : 1

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Transfer Case Drain Plug	39	29	-
Transfer Case Fill Plug	39	29	-
Transfer Case Half Bolts	29	21	-
Transfer Case Heat Shield Bolts	11	-	97
Transfer Case Rear Output Drive Gear Nut	235	173	-
Transfer Case Rear Output Drive Shaft Housing Bolts	29	21	-
Transaxle Rear Mount Retaining Bolts	90	66	-
Transaxle Rear Mount-to-Bracket Through Bolt	90	66	-
Rear Transaxle Bracket Mounting Bolts and Nut	90	66	-
Lower Transfer Case Bolts	75	55	-
Upper Transfer Case Bolt	75	55	-
Transfer Case Brace Bolts (For All Engines)	60	44	-
Transfer Case Bracket Bolts (Callout : 5) (For All Engines)	60	44	-
Transfer Case Bracket Bolt (Callout : 6) (For Only HFV6 3.2L)	40	30	-

SPECIAL TOOLS

Special Tools Table

	DT-48074 Input and Output Shaft Seal Installer
	DT-48075 Output Shaft Seal Installer
	DT-48076 Rock Guard Installer
	DT-48077 Output Shaft Slinger Installer
	DT-48078 Inner Drive Shaft Seal Installer
	DT-48094 Inner Drive Shaft Seal Protector
	DT-48146 Press Support
	J-5590 Pinion Bearing Race Installer - Rear
	J-8092 Driver Handle
	J-08614-A Pinion Flange Holder and Remover
	J-29873 Injector Nozzle Socket 30mm
	J-45124 Removal Bridge
	J-22912-01 Universal Bearing Puller
	J-25070 Heat Gun - 500 - 750F
	J-26941 Bushing and Bearing Remover

DIAGNOSIS

Visual/Physical Inspection

Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause the symptom.
Inspect for the correct lubricant levels and the proper viscosities.
Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed, road conditions, ambient temperature, and other specifics.
Compare the driving characteristics or sounds, if applicable, to a known good vehicle and ensure you are not trying to correct a normal condition.

Intermittent Symptom

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom Diagnosis

Noisy in Drive

Cause	Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement.
Water or contamination within the lubricant Water or contamination within the lubricant, causing excessive torque converter clutch slip rate, may create a grind, growl,or moan in the rear differential under light or steady load conditions.	Replace the lubricant and flush the transfer case of thecontaminated fluid.
Loose propeller shaft mounting bolts	Tighten the bolts, as required.
Worn propeller shaft constant velocity joints	Replace propeller shaft assembly.
Worn axle shaft constant velocity joints	Replace the constant velocity joints, as required.
Incorrect gear oil in the transfer case	Replace with gear oil.
Bearing noise within the transfer case A grinding or roar type noise will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required.
Gear set whine noise within the transfer case Whine type noises will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required. Contributing factors may include : Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Noisy When Coasting

Cause	Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement.
Loose propeller shaft mounting bolts	Tighten the bolts, as required.
Worn propeller shaft constant velocity joints	Replace the propeller shaft assembly.
Worn axle shaft constant velocity joints	Replace the constant velocity joints, as required.
Incorrect gear oil in the transfer case	Replace with gear oil.
Bearing noise within the transfer case A grinding or roar type noise will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required.
Gear set whine noise within the transfer case Whine type noises will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required. Contributing factors may include : Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Intermittent Noise

Cause	Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement.
Loose propeller shaft mounting bolts	Tighten the bolts, as required.
Incorrect gear oil	Replace with gear oil.

Constant Noise

Cause	Correction
Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement.
Low gear oil levels	Faulty oil seals or other type of external leaks may contribute to lower than required fluid levels. Refer to Transfer Case Leak Diagnosis. Fill to proper level with gear oil.
Worn propeller shaft constant velocity joints	Replace the propeller shaft assembly.
Bearing noise within the transfer case A grinding or roar type noise will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required.
Gear set whine noise within the transfer case Whine type noises will increase or decrease relative to the vehicle speed.	Inspect for the proper fluid level. Fill, as required. If the noise continues, repair or replace the internal components, as required. Contributing factors may include : Incorrect backlash between the gear sets Worn or damaged gear teeth Transaxle assembly noise Rear differential noise

Transfer Case Leak Diagnosis

Cause	Correction
Worn, scored, or missing drain and/or fill plug	Install new plugs and tighten the plugs per specifications.
Worn or damaged input or output shaft oil seal	Replace the output shaft oil seal, as required.
Cut or damaged output housing O-ring seal	Replace the O-ring seal, as required.
Worn internal shaft oil seals Worn or damaged internal shaft oil seals may be detected by a fluid leak at the vent hole area on the bottom of the cover.	Replace the oil seals, as required.
Cut or damaged transaxle assembly-to-transfer case O-ring seals	Replace the O-ring seals, as required.
Cases or housings porosity or leaking seal surfaces	Replace the transfer case assembly if it cannot be repaired.

COMPONENT LOCATOR

Transfer Case Disassembled View

Transfer Case Drain Plug
Transfer Case Fill Plug
Transfer Case Input Shaft Seal - Left
Transfer Case O-Ring Seal
Transfer Case - Left
Transfer Case Vent Assembly
Transfer Case Half Locating Pin
Front Wheel Drive Shaft Shield
Half Shaft Retainer
Front Wheel Drive Retainer
O-Ring
Front Wheel Drive Intermediate Shaft Bearing Retainer
Front Wheel Drive Intermediate Shaft Bearing Assembly
Front Wheel Drive Intermediate Shaft
Transfer Case Mounting Bracket Bolt
Transfer Case Mounting Bracket
Transfer Case Heat Shield Bolt
Transfer Case Heat Shield
Transfer Case Half Bolt
Transfer Case - Right
Transfer Case Seal
Transfer Case Input Shaft Seal - Right
Front Drive Axle Intermediate Shaft Seal Assembly
Transfer Case Input Shaft
Transfer Case Rear Output Drive Shaft
Transfer Case Rear Output Drive Gear Nut
Transfer Case Rear Output Shaft Flange
Transfer Case Rear Output Shaft Oil Slinger
Transfer Case Rear Output Shaft Seal
Transfer Case Rear Output Shaft Bearing Assembly
Transfer Case Rear Output Drive Housing
Transfer Case Rear Output Shim
Transfer Case Rear Output Drive Shaft Housing Bolt
Transfer Case Rear Output Shaft Bearing Spacer
Transfer Case Rear Output Shaft
Transfer Case Rear Output Drive Shaft Housing Seal O-Ring