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Transfer Case - Nvg 900: Removal & Installation Saturn VUE I

Transfer Case ~1868 words

Axle Shaft Oil Seal Replacement

Tools Required

J 44809 Output Shaft Seal Installer

  1. Carefully pry out the output shaft seal and discard.
  2. Remove the old seal material from the seal bore area by cleaning the area.
  3. Using the J 44809 , install the NEW output shaft seal.
  4. Check the fluid level. Fluid level should be to the bottom of the fill plug hole threads.
  5. Clean the drain plug.
  6. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads. Tighten: Tighten the fill plug to 15 N.m (11 lb ft).

Pinion Oil Seal Replacement

Tools Required

  1. J 44872 Pinion Shaft Seal Installer. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  2. J 44873 Shoulder Bolts
  3. J 44882 Pinion Press Support Bar. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .

Removal Procedure

  1. Remove the 3 bolts from the bracket (1).
  2. Remove the bracket (1).
  3. Remove the drain plug (1).
  4. Remove the fill plug (1) and drain the fluid.
  5. Install J 44873 and the 2 attaching bolts to the pinion flange.
  6. Using a breaker bar and a ratchet with a 27 mm socket, remove the pinion nut.
  7. Insert J 8614-01 (1) through the slots in J 44873 .
  8. Turn the blue collar until it locks into the grooves on the underside of the J 44873 .
  9. Tighten the forcing screw to remove the pinion flange.
  10. Remove the J 44873 (2), the 2 attaching bolts and J 8614-01 (1) from the pinion flange.
  11. Remove the oil seal (1) and slinger washer (2) from the housing.
  12. Remove all bolts (2) from the side cover (1).
  13. Use the pry point relief slots to remove the cover.
  14. Remove the carrier assembly (1) from the housing.
  15. Using the bolts supplied, attach J 44882 to the carrier housing. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  16. Tighten the forcing screw in order to push out the pinion gear. The gear will spin when it is being pushed out. When the gear stops spinning, stop pushing. The gear teeth will contact the housing.
  17. Remove the J 44882 . See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  18. Install the old pinion nut on the threads of the pinion shaft. Hold the shaft so the gear head faces up and drive out the pinion shaft so that it does not contact the housing.
  19. Remove the bearing (1), collapsible spacer (2), and pinion shaft (3) from the housing.

Installation Procedure

  1. Install the NEW collapsible spacer (2) onto the pinion shaft (3).
  2. Install the pinion shaft (3) into the housing.
  3. Install the bearing (1) onto the pinion shaft.
  4. Install the slinger washer (2) and the NEW pinion seal (1) to the housing.
  5. Using the J 44872 , install the NEW pinion seal. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  6. Using a NEW pinion nut (1), install the pinion flange (2) to the pinion shaft.
  7. Install J 44873 and the 2 bolts supplied in order to hold the pinion flange while tightening the nut.
  8. Tighten the pinion flange nut until it is snug.
  9. Tighten the nut slowly in order to crush the collapsible spacer. Tighten: Tighten the pinion flange nut to achieve a rotating torque of 0.9-1.6 N.m (8-14 lb in).
  10. Clean the carrier assembly housing sealing surface (1) with solvent and scrape it clean with a razor blade.
  11. Clean the cover sealing surface (1) with solvent and scrape it clean with a razor blade.
  12. Install the carrier assembly (1) to the housing.
  13. Apply a 2-3 mm (0.08-0.12 in) amount of sealer Saturn P/N 1052943 or equivalent to the housing (1).
  14. Install the side cover (1) and bolts (2 and 3) to the housing. There is not a specific tightening sequence, but the bolts with dowel pins should be tightened first, and alternate the others from side to side. Tighten: Tighten the side cover bolts to 37 N.m (27 lb ft).
  15. Install the drain plug. Apply sealant Saturn P/N 21485278 to the threads. Tighten: Tighten the drain plug to 24 N.m (18 lb ft).
  16. Fill the transfer case with fluid, after it is installed in the vehicle, to the bottom of the fill plug hole, or 540 ml (18.2 oz).
  17. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads. Tighten: Tighten the fill plug to 15 N.m (11 lb ft).

Differential Carrier Seal Replacement

Tools Required

  1. J 44871 Hub Seal Installer. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  2. J 44875 Right Bearing Race Installer. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  1. Remove the 3 bolts from the bracket (1).
  2. Remove the bracket (1).
  3. Remove the drain plug (1).
  4. Remove the fill plug (1) and drain the fluid.
  5. Remove all bolts (2) from the side cover (1).
  6. Use the pry point relief slots to remove the cover.
  7. Remove the carrier assembly (1) from the housing.
  8. Remove the bearing cup (1), shims (2) and seal (3) from the cover (4). Mark or tag the cup (1) and shims (2) for proper assembly.
  1. Using J 44871 and a driver handle, install the inner oil seal into the cover. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  2. Install the shim (2) and the bearing cup (3) into the side cover (1).
  3. Using J 44875 and a driver handle, install the cup and the shim. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  4. Drive the seal (1) out from the inside of the carrier assembly housing.
  5. Using J 44871 and a driver handle, install the oil seal to the housing. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  6. Clean the carrier assembly housing sealing surface (1) with solvent and scrape it clean with a razor blade.
  7. Clean the cover sealing surface (1) with solvent and scrape it clean with a razor blade.
  8. Install the carrier assembly (1) to the housing.
  9. Apply a 2-3 mm (0.8-0.12 in) amount of sealer Saturn P/N 1052943, or equivalent, to the housing (1).
  10. Install the side cover (1) and bolts (2 and 3) to the housing. Tighten: Tighten the side cover bolts to 37 N.m (27 lb ft).
  11. Install the drain plug. Apply sealant Saturn P/N 21485278 to the threads. Tighten: Tighten the drain plug 24 N.m (18 lb ft).
  12. Fill the transfer case with fluid, after it is installed in the vehicle, to the bottom of the fill plug hole, or 540 ml (18.2 oz).
  13. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads. Tighten: Tighten the fill plug 15 N.m (11 lb ft).

Front Drive Axle Inner Stub Shaft Bearing Replacement

Tools Required

  1. J 29369-2 Bushing/Universal Remover. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  2. J 4972-4 Output Shaft Needle Bearing Installer. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  1. Remove the 3 bolts from the bracket (1).
  2. Remove the bracket (1).
  3. Remove the drain plug (1).
  4. Remove the fill plug (1) and drain the fluid.
  5. Remove all bolts (2) from the side cover (1).
  6. Use the pry point relief slots to remove the cover.
  7. Remove the carrier assembly (1) from the housing.
  8. Using J 29369-2 and a slide hammer, remove the stub shaft inner bearing (1) from carrier bore. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) . OTC 8007 adaptors may be needed to assist in the removal.
  9. Using J 4972-4 and a driver, install the axle shaft bearing (1) to the carrier until the bearing seats. See «Special Tools and Equipment»(ref-188831-S26875754172005090200000) .
  10. Clean the carrier assembly housing sealing surface (1) with solvent and scrape it clean with a razor blade.
  11. Clean the cover sealing surface (1) with solvent and scrape it clean with a razor blade.
  12. Install the carrier assembly (1) to the housing.
  13. Apply a 2-3 mm (0.8-0.12 in) amount of sealer Saturn P/N 1052943 or equivalent to the housing (1).
  14. Install the side cover (1) and bolts (2 and 3) to the housing. There is not a specific tightening sequence, but the bolts with dowel pins should be tightened first, and alternate the others from side to side. Tighten: Tighten the side cover bolts to 37 N.m (27 lb ft).
  15. Install the drain plug. Apply sealant Saturn P/N 21485278 to the threads. Tighten: Tighten the drain plug 24 N.m (18 lb ft).
  16. Fill the transfer case with fluid, after it is installed in the vehicle, to the bottom of the fill plug hole, or 540 ml (18.2 oz).
  17. Install the fill plug. Apply sealant Saturn P/N 21005994 to the threads. Tighten: Tighten the fill plug 15 N.m (11 lb ft).
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Remove the right hand axle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-188827-S42461363522005090200000) in Wheel Drive Shafts.
  3. Remove the bolts from the power take-off unit (PTU) brace and engine.
  4. Remove the brace.
  1. Position brace to the vehicle and hand start all bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  2. Install the right hand axle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-188827-S42461363522005090200000) in Wheel Drive Shafts.

Transfer Case Replacement

Tools Required

  1. J 44017 Shaft Remover
  2. SA9133T Slide Hammer
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-188813-S15240900572005090200000) in General Information.
  2. Remove the intermediate drive shaft. Refer to «Intermediate Shaft Replacement (L61)»(ref-188827-S37595883102005090200000) or «Intermediate Shaft Replacement (L66)»(ref-188827-S03439030982005090200000) in Wheel Drive Shafts.
  3. Disengage the PTU stub shaft from the PTU using the J 44017 and SA9133T .
  4. Remove the propshaft center bearing to underbody bolts.
  5. Remove the front propshaft attachment bolts.
  6. Compress the CV joint and disengage the propshaft from the PTU and secure with wire.
  7. Separate the steering gear from the cradle for clearance. Refer to «Power Steering Gear Replacement»(ref-188802-S09464702742005090200000) .
  8. Remove the rear powertrain mount bracket bolts from the PTU.
  9. Remove the PTU brace bolts and remove the brace.
  10. Remove the PTU to transmission bolts.
  11. Remove the PTU vent hose.
  1. Inspect the transmission output shaft seal, replace if damaged.
  2. Install the PTU to transmission. Ensure the PTU is fully engaged. Hand start the PTU to transmission bolts. DO NOT tighten.
  3. Install the PTU brace. Hand start all 6 bolts.
  4. Tighten the PTU to transmission bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  5. Tighten the PTU brace bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  6. Hand start all the powertrain mount to PTU bolts and tighten.
  7. Hand start the propshaft center bearing bolts.
  8. Ensure all the PTU flange and propshaft coupling area is clean. Insert coupling into the PTU flange.
  9. Hand start all propshaft coupling bolts and tighten. Tighten: Tighten the bolts to 25 N.m (19 lb ft).
  10. Install the center bearing bolts. Tighten: Tighten the bolts to 25 N.m (19 lb ft).
  11. Install the intermediate drive shaft. Refer to «Intermediate Shaft Replacement (L61)»(ref-188827-S37595883102005090200000) or «Intermediate Shaft Replacement (L66)»(ref-188827-S03439030982005090200000) in Wheel Drive Shafts.
  12. Position the steering gear mounts to the cradle. Refer to «Power Steering Gear Replacement»(ref-188802-S09464702742005090200000) .
  13. Install the PTU vent hose.
  14. Check the PTU fluid fill. Remove the fluid fill plug. Fill until fluid is just below the bottom of the fill hole. Specification: Add 500 ml (17 oz) PTU fluid. Tighten: Tighten the fill plug to 15 N.m (11 lb ft).
  15. Lower the vehicle.
  16. Start the engine and observe idle shape. Compare to pre-removal condition. If excessive, perform powertrain balance procedure-operation #1. Refer to Powertrain Balance procedure.
  17. Check the transmission oil level and fill as required. Refer to «Transmission Fluid Replacement»(ref-188804-S13658497612005090200000) in Automatic Transmission - VT25-E.

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