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Transfer Case - MJ8: Overhaul Saturn VUE I

Transfer Case 2 illustrations ~710 words

Transfer Case Disassemble

Tools Required

J 44873 Pinion Flange Holder and Remover

  1. Remove the ventilation valve (408), hose (407) and clamps (406).
  2. Remove the drain plug (403) and washer (404).
  3. Remove the fill plug (401) and washer (402).
  4. Remove the bolts (102) and cover (101).
  5. Remove the seal (305) and O-ring (304).
  6. Remove the locating pin (105).
  7. Remove the input gear (214).
  8. Remove the bearing (217) and 25 mm shim (216).
  9. Mark or tag the shim (216) for assembly.
  10. Secure the case in a vise with soft jaws.
  11. Using a chisel, cut the locking tab on the locknut (210).
  12. Install the J 44873 and bolts to the output yoke. Tighten: Tighten the bolts to 48 N.m (35 lb ft).
  13. Loosen the locknut.
  14. Remove the J 44873 and bolts.
  15. Remove the nut (210), washer (209), sealing washer (303), O-ring (302), and output yoke (208). Note the washer (209) installed position.
  16. Remove the output shaft (201) with bearing, collapsible spacer (204) and washers (215).
  17. Remove the seal (301) and bearing (207).

Transfer Case Assemble

Tools Required

  1. DT 46429 Oil Seal Driver. See «Special Tools and Equipment»(ref-188836-S04359754522005090200000) .
  2. DT 46512 Seal Installer. See «Special Tools and Equipment»(ref-188836-S04359754522005090200000) .
  3. EN 46342 Driver Handle. See «Special Tools and Equipment»(ref-188836-S04359754522005090200000) .
  4. J 44873 Pinion Flange Holder and Remover
  1. Lubricate all internal components with GM P/N 12578261 (Canadian P/N 10953455) prior to assembly.
  2. Use the EN 46342 (1) DT 46429 (2) in order to install the bearing (207) and seal (301). See «Special Tools and Equipment»(ref-188836-S04359754522005090200000)
  3. Install the output shaft (201) with bearing, NEW collapsible spacer (204) and washers (215). Note the proper installation direction of the spacer (204).
  4. Lubricate the threads of the output shaft with GM P/N 12378261 (Canadian P/N 10953455).
  5. Install the output yoke (208), NEW O-ring (302), NEW sealing washer (303), NEW washer (209) and NEW locknut (210).
  6. Secure the case in a vise with soft jaws.
  7. Install the J 44873 and bolts. Tighten: Tighten the bolts to 48 N.m (35 lb ft).
  8. Tighten the locknut to 108-294 N.m (75.6-217 lb ft) while measuring the rotating torque. Tighten the nut to achieve a rotating torque of 1.15-1.71 N.m (10.2-15.1 lb in). If the rotating torque exceeds 1.71 N.m (15.1 lb in), replace the collapsible spacer and reassemble. If the locknut tightening torque exceeds 294 N.m (217 lb ft), replace the collapsible spacer and reassemble.
  9. Remove the J 44873 and bolts.
  10. Stake the locknut using a 3.5 mm (0.138 in) punch.
  11. Install the input gear (214) with shim (216) and bearing (217) into the case.
  12. Use the EN 46342 (1) and the DT 46512 (2) in order to install the oil seal into the cover. See «Special Tools and Equipment»(ref-188836-S04359754522005090200000) . Install the seal until the flat surface of the seal measures 0.00-1.0 mm (0.00-0.04 in) flush with or slightly above the surface of the cover (a).
  13. Install a NEW O-ring (304) to the cover.
  14. Install the cover (101) and bolts (102). Tighten: Tighten the bolts to 26 N.m (20 lb ft).
  15. Install the locating pin (105).
  16. Install the fill plug (401) and NEW washer (402).
  17. Install the drain plug (403) and NEW washer (404). Tighten: Tighten the drain plug to 44 N.m (33 lb ft).
  18. Install the ventilation valve (408), hose (407) and clamps (406).
  19. Recheck the unit for proper assembly. Refer to «Transfer Case Assembly Inspection»(ref-188836-S17115447012005090200000) .

Scheme 15

Scheme 15: Transfer Case Description and Operation
Scheme 15: Transfer Case Description and Operation

The Honda AWD transfer case (1) is mated to the rear side of the 5-speed automatic transmission assembly beside the differential. The transfer case assembly consists of an aluminum case and side cover and drive and driven gears. The gear set is a hypoid design. Both the drive and driven gear shafts are supported by tapered roller bearings. Pinion depth, gears backlash, and bearing preloads are adjusted during production using 25, 40, and 80 mm shims of various thickness. The internal components of the transfer case are lubricated by hypoid gear oil.

Scheme 16

Scheme 16
Scheme 16

The transmission (1) differential drive gear rotates the transfer output sub-shaft (2). The transfer output sub-shaft is splined to and drives the transfer case input gear (3). The transfer case output shaft (4) transfers power through the output flange to the Variable Torque Management rear differential (6) via a 2-piece propeller shaft assembly (5).

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