Sealers, Adhesives, and Lubricants
| Application | Type of Material | Saturn Part Number |
|---|---|---|
| United States | ||
| Drain Plug Threads | Sealant | 21485278 |
| Fill Plug Threads | Sealant | 21005994 |
| Gear Lubricant GM Versatrak | Synthetic Gear Oil | 12378514 |
| Side Cover-to-Housing | Sealant | 1052943 |
| Side Cover Bolts | Thread Locker | 12345382 |
Sealers, Adhesives, and Lubricants
Scheme 13
| Callout | Component Name |
|---|---|
| 1 | Nut |
| 2 | Flange |
| 3 | Oil Seal |
| 4 | Slinger Washer |
| 5 | Bearing |
| 6 | Bearing Cup |
| 7 | Axle Shaft Oil Seal - Left Side |
| 7 | Axle Shaft Oil Seal - Right Side |
| 8 | Housing |
| 9 | Vent |
| 10 | Hollow Dowel |
| 10 | Hollow Dowel |
| 11 | Collapsible Spacer |
| 12 | Bearing Cup |
| 13 | Bearing |
| 14 | Shim |
| 15 | Pinion Shaft |
| 16 | Vent Baffle |
| 17 | Shim |
| 18 | Cup |
| 19 | Differential Bearing |
| 20 | Ring Gear |
| 21 | Differential Case |
| 22 | Bolt |
| 23 | Inner Bearing |
| 24 | Bearing |
| 25 | Bracket |
| 26 | Bolts |
| 27 | Fill Plug |
| 28 | Axle Shaft Oil Seal - Right Side |
| 29 | Bolt |
| 30 | Side Cover |
| 31 | Shim |
| 32 | Bearing Race |
| 33 | Drain Plug |
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.
Noisy in Drive
| Cause | Correction |
|---|---|
| Inspect for the proper gear oil levels prior to performing system diagnosis. | |
| Loose propeller shaft constant velocity joints | Tighten the bolts as required. Refer to Propeller Shaft Replacement in Propeller Shaft. |
| Worn propeller shaft constant velocity joints | Replace the propeller shaft assembly. Refer to Propeller Shaft Replacement in Propeller Shaft. A worn propeller shaft constant velocity joint may create a clicking, grinding, or snapping type of noise. |
| Worn or loose center bearing assembly | Replace the center bearing assembly as required. A worn center bearing assembly may cause vehicle vibration or a grinding or squealing type of noise. |
| Worn universal joints | Replace the universal joints as required. A worn universal joint may create a clicking or snapping type of noise. |
| Worn axle shaft constant velocity joints | Replace/repair the constant velocity joints as required. A worn axle constant velocity joint may create a clicking, grinding, or snapping type of noise. |
| Rear axle noise | Refer to Diagnostic Starting Point - Transfer Case . |
| Loose mounting bracket | Tighten the bracket bolt or replace the bracket as required. |
| Loose transfer case-to-transmission mounting bolts | Tighten the bolts as required. |
| Incorrect gear oil | Replace with GM gear oil Saturn P/N 12378514. |
| Bearing noise within the transfer case | A grinding or roar type noise will increase or decrease relative to the vehicle speed. Check for proper fluid level. Fill as required. If the noise continues, replace the unit. |
| Gear set whine noise within the transfer case | Whine type noises will increase or decrease relative to the vehicle speed, approximately 80-90 km/h (50-60 mph). Check 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 axle noise |
Noisy in Drive
Noisy When Coasting
| Cause | Correction |
|---|---|
| Inspect for the proper gear oil levels prior to performing system diagnosis. | |
| Loose propeller shaft mounting bolts. | Tighten the bolts as required. Refer to Propeller Shaft Replacement in Propeller Shaft. |
| Worn propeller shaft constant velocity joint | Replace the propeller shaft assembly. Refer to Propeller Shaft Replacement in Propeller Shaft. A worn propeller shaft constant velocity joint may create a clicking, grinding, or snapping type of noise. |
| Worn or loose center bearing assembly | Replace the center bearing assembly as required. A worn center bearing assembly may cause vehicle vibration or a grinding or squealing type noise. |
| Worn universal joints | Replace the universal joints as required. A worn universal joint may create a clicking or snapping type noise. |
| Worn axle shaft constant velocity joints | Replace/repair the constant velocity joints as required. A worn axle shaft constant velocity joint may create a clicking, grinding, or snapping type noise. |
| Rear axle noise | Refer to Diagnostic Starting Point - Rear Drive Axle in Rear Drive Axle. |
| Loose mounting bracket | Tighten the bracket bolts or replace the bracket as required. |
| Loose transfer case-to-transmission mounting bolts. | Tighten the bolts as required. |
| Incorrect gear oil | Replace with GM gear oil Saturn P/N 12378514. |
| Bearing noise within the transfer case | A grinding or roar type noise will increase or decrease relative to the vehicle speed. Check for proper fluid level. Fill as required. If the noise continues, replace the unit. |
| Gear set whine noise within the transfer case | Whine type noises will increase or decrease relative to the vehicle speed, approximately 80-90 km/h (50-60 mph). Check for 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 axle noise |
Noisy When Coasting
Housings
- Clean all case/housings in solvent.
- Inspect for the following: Damaged gasket sealing surfaces (1) A loose, damaged, or restricted vent tube (2) Worn, scored, or loose bearing races or worn bearing race bores (3) Damaged drain plug (5) Damaged fill plug hole threads (4) Damaged bolt threads (6) Damaged oil seal bores (7)
Gears and Shafts
- Clean the gears and shafts in solvent.
- The ring gear and pinion must be inspected for proper wear and pattern. The end of the gear tooth farthest away from center of ring gear (1) is the heel end of the tooth. The end of the gear tooth nearest center of ring gear (2) is the toe end of the tooth. The side of the tooth that curves inward or is concave (3) is considered the coast side of the tooth. The side of the tooth that curves outward or is convex (4) is considered the drive side of the tooth.
- Inspect the pinion shaft for the following: Wear, pitting, or discoloration by heat on the gear teeth (1) Worn or scored shaft (2) Worn or damaged splines (3) Damaged threads (4) Worn bearings (5)
- Inspect the pinion flange seating surface (2) for wear, damaged bolt threads (3) and worn or damaged splines (1).
Bearings and Races
- Inspect the bearing rollers and races for the following: Pitting Scoring or grooves Excessive wear or other damage
- Inspect bearing rollers and races for heat discoloration. Heat discoloration ranges from a faint yellow to a dark blue color. This discoloration may result from an overload or improper lubrication. Excessive heat causes softening of the rollers and races. Bearing races with a sign of heat discoloration must be replaced.
Scheme 14
The transfer case (PTU) in this vehicle consists of an aluminum housing and a ring and pinion power transfer system.
The PTU transfers torque/power to the rear differential, gerotor pump design, via a two-piece propshaft assembly.
The on-demand rear differential distributes variable torque/power to the rear wheels via individual axle shafts.
The on-demand system operates as follows: only when front wheel slippage is encountered torque/power is proportioned to the rear wheels, as long as there is not front-to-rear speed difference; there is no torque/power to the rear wheels.
When front-to-rear wheel slippage does not occur, the rear differential, gerotor, pumps fluid stored in the sump to a piston that actuates a clutch pack, which then distributes torque/power to the rear wheels.