Service Information Regarding Transfer Case, Propeller Shaft and Rear Differential Assembly Exchange Program

The purpose of this bulletin is to outline the Transfer Case, Propeller Shaft, and Rear Differential Assembly exchange program for the 2002 model year Saturn VUE, equipped with AWD. The exchange program will be administered through May 31, 2002.

Important: For effective engineering analysis do not disassemble the removed unit or loosen any fasteners other than those listed on the Authorized AWD Component Repairs list.

The AWD component exchange program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.

The AWD component exchange program will be administered through Saturn Service Parts Operations and the GM Warranty Parts Center (WPC).

If any component(s) of the Transfer Case, Propeller Shaft, or Rear Differential Assembly, other than those listed on page 3, require repair or replacement, the assembly must be exchanged.

The Transfer Case, Propeller Shaft, and Rear Differential Assemblies are highlighted in the illustration above. Components on the Authorized AWD Component Repairs list must be serviced according to the repair procedures in the 2002 Saturn VUE Chassis Service Manual.

There are certain repairs that can be performed on the AWD system that do not require an assembly of the AWD system to be exchanged. During the six-month AWD assembly exchange program period, Retailers may replace any of the components listed below without exchanging the Transfer Case Assembly, Propeller Shaft, or Rear Differential Assembly.

Oil leaks coming from any component(s) on the list above should be repaired at the Retailer without exchanging the Transfer Case or Rear Differential Assembly. Verify the source of the oil leak, if the Transfer Case or Rear Differential Assembly has an oil leak that is not coming from a component(s) listed above, the Transfer Case or Rear Differential Assembly must be exchanged.

Important: Transfer Case, Propeller Shaft, or Rear Differential assembly damage or failures that are caused by circumstances or components external to the assemblies that are not considered a warranty repair, such as a collision, will not fall under the exchange program.

A thorough diagnosis must be performed on the complaint condition in order to prevent unnecessary component replacements. Refer to AWD diagnostic procedures in the 2002 Saturn VUE Chassis Service Manual. Please complete the enclosed worksheet on page 11 of this bulletin prior to removing the assembly. Upon complete diagnosis of the Transfer Case, Propeller Shaft or Rear Differential Assembly, order a replacement part through the normal SRS ordering process. The SRS system will prompt for a VIN and vehicle mileage.

The removed assembly must be returned complete in the original exchange assembly shipping container. For effective engineering analysis, please do not remove any components. Retail facilities that return an assembly that has been disassembled or partially disassembled will be billed for all materials furnished.

The GM Warranty Parts Center (WPC) will be requesting the return of these cores via an Exchange Program Special Part Request form which will be faxed to the attention of the Retailer's Parts Manager for processing. The WPC Customer Assistance office is available to answer inquires regarding parts return and shipment tracking for this program. Telephone number is (248) 371-9901/9902.

Important: Do not ship a component to the WPC without an official request.

When a Saturn Retailer orders an exchange assembly from SSPO, SSPO will arrange to ship a new unit to the Retailer overnight at no charge.

Notice: Transfer Case and Rear Differential Assembly Exchange units will be shipped without oil; fill and check oil level before operating the vehicle. Use only GM VERSATRAK fluid.

The Transfer Case and Rear Differential Assembly units require GM VERSATRAK fluid GM P/N 12378514 in Canada use (P/N 88901045). Assembly Fluid Requirements:

The 0.5L (0.53 qt) containers may be ordered from SSPO. Any other oil will create operating concerns requiring future replacement of the assembly.

Exchange units will also be shipped with return shipping instructions, including a return shipping label (freight collect at destination).

1. Add 750 ml. (1.56 pt) GM VERSATRAK fluid to rear differential assembly. Refer to illustration on page 6 for fill plug location

Checking Rear Differential Assembly fluid for proper level requires that the internal pump and clutch assembly be primed with fluid. One of the priming methods must be completed prior to checking the Rear Differential Assembly fluid level.

2. On-Hoist Priming Method

Prime internal pump and clutch assembly using hoist.

Caution: Make sure vehicle is properly supported and squarely positioned on the hoist.

2.1.	Position vehicle on hoist and raise vehicle, by the frame so that all four wheels hang free.

2.2.	Start engine and place in drive.

2.3.	Release brake pedal so that all four wheels spin.

2.4.	Slowly apply the parking brake just enough to stop the rear wheels from spinning.

Important: Do not exceed more than five seconds of parking brake apply. The rear differential assembly clutches are in a slipping condition and are generating heat.

2.5.	Apply throttle until the rear wheels start to spin again for five seconds maximum.

2.6.	Release the parking brake and bring vehicle wheels to a stop.

2.7.	Put vehicle in park and turn vehicle off.

or

3. On-Road Priming Method

Drive vehicle on a paved flat surface in a 360° circle for three consecutive revolutions at 8 km/h (5 mph)

Caution: Make sure vehicle is properly supported and squarely positioned on the hoist.

4. Position vehicle on hoist and raise vehicle.
5. Make sure vehicle is level



6. Clean area around rear axle fill plug.
7. Remove rear axle fill plug



8. Fabricate a dipstick from a pipe cleaner or similar item. Refer to illustration above.
9. Insert dipstick into fill plug opening as shown.
10. Remove dipstick and measure distance from bend in dipstick to GM VERSATRAK Fluid level. Distance between bend and GM VERSATRAK Fluid level (1) should be 8-17 mm (.32 - .68 in). Refer to illustration shown.
11. Add or remove fluid as required. Too much or too little GM VERSATRAK Fluid may have an adverse effect on the operation of the all wheel drive system.
12. Apply thread sealer P/N 21485278 or equivalent to the threads of the rear axle fill plug.
13. Install and tighten rear axle fill plug.

Tighten
Tighten the rear axle fill plug to 20 N·m (15 lb ft).

14. Lower vehicle.
15. Inspect for leaks.

1. Drain fluid from the defective assembly.



2. Refer to illustrations above for drain plug locations.
3. Remove the assembly as outlined in the 2002 Saturn VUE Chassis Service Manual.
4. To ensure all fluid is drained from defective assembly, tilt assembly towards drain plug location.
5. Remove propeller shaft guard from defective rear differential assembly and install guard onto new rear differential assembly.

Tighten
Tighten the propeller shaft guard-to-rear differential assembly bolts to 25 N·m (18 lb ft).

6. Re-torque any fasteners that were loosened or removed to the original torque specification. Refer to 2002 VUE Chassis Service Manual for correct torque specifications.
7. Remove any plastic shipping plugs and covers from the exchange assembly and install them onto the removed assembly.
8. If the unit is being returned for an oil leak, mark the position of the leak on the assembly with a permanent marker.
9. Complete the component ID tag and attach tag to the component being returned.
10. Place the removed assembly into the exchange assembly shipping container.
11. Place a copy of the service order and completed feedback form contained with the exchange assembly in the envelope provided and attach the envelope to the return assembly.
12. Place retailer address (return address) and WPC case number on the outside of shipping container.

Remove the original shipping tag and attach the prepaid return shipping label to the container. The UPS shipping label provided with the exchange assembly is the only shipping document required to return the assembly core. The tracking number from the lower portion of the UPS label should be retained for Retailer records. This copy is your only proof that the removed unit was returned.

Important: To make arrangements to have a Transfer Case, Propeller Shaft, or Rear Differential Assembly core picked up, contact your local United Parcel Service (UPS) office. ALL UNITS ARE REQUIRED TO BE RETURNED USING THE PROCESS OUTLINED IN THIS BULLETIN.

Please ensure the Retailer address (return address) and the WPC case number can be identified on the outside of the container.

If the envelope containing the shipping information is lost, contact the Saturn Service Parts Assistance Center at 1-800-828-2112, prompt 2.

To receive credit for replacing a Transfer Case, Propeller Shaft, or Rear Differential Assembly during the unit exchange program, submit a claim with the following information:

Important: Applicable miscellaneous parts, such as fluids, are to be sold to the customer service order (CSO) following standard CSO preparation procedures.

* Unit exchange program administrative allowance.

** Unit exchange program administrative allowance.

Refer to Paper version of this bulletin for the original form "Attachment 1"