Exchange Program - Limited Service Repair Program for the All-Wheel Drive (AWD) Transfer Case Assembly (RPO MJ8)

This bulletin is being revised to add the 2006 model year. Please discard Corporate Bulletin Number 03-07-30-039A (Section 07 -- Transmission/Transaxle).

The purpose of this bulletin is to outline the level of service for 2004, 2005, and 2006 Saturn VUE vehicles equipped with AWD transfer case assembly (RPO MJ8).

The Limited Service Repair Program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.

Important: To facilitate effective engineering analysis, do not disassemble the removed transfer case assembly or loosen any supporting fasteners. Also, be sure to completely fill out the Core Return Tag (item # S0399300) before returning any parts to the SSPO Core Return Center (in Canada, use the normal core return process to return to your servicing PDC).

AWD TRANSFER CASE ASSEMBLY (RPO MJ8) REPLACEMENT PROGRAM PROCESS

Important: Do not remove any unauthorized components from the case, covers, or shafts. Do not remove/replace any unauthorized fasteners from the transfer case assembly as the fastener torque data may assist in determining the cause of the leak.

The Limited Service Repair Program for the AWD transfer case (RPO MJ8) is for the life of the product.

Important: To facilitate effective engineering analysis, do not disassemble the press-fit bearing races and/or shims from the case and cover. Do not disassemble the press-fit bearings and shims from the shafts. Do not disassemble the ventilation baffle and retaining bolt. Also, be sure to completely fill out the Core Return Tag (item # S0399300) before returning any parts to the SSPO Core Return Center (in Canada, use the normal core return process to return to your servicing PDC).

AUTHORIZED TRANSFER CASE COMPONENT REPAIRS

Currently, authorized repairs on the AWD transfer case assembly (RPO MJ8) include all components as identified in the illustrations below. If the gears, shims, bearings, or bearing races of the AWD transfer case assembly (RPO MJ8) require replacement, the complete transfer case must be replaced as an assembly.

FLUID LEAK(S)

1. Verify the fluid leak is actually hypoid gear oil. Refer to "Transfer Case Leak Diagnosis in Transfer Case-MJ8" in the 2004, 2005, or 2006 Saturn VUE Service Manual.
2. Be sure to mark the exact location of the leak(s) on the AWD transfer case assembly (RPO MJ8) with a permanent marker or paint stick.

REMOVAL AND INSTALLATION PROCEDURE

Refer to the AWD transfer case (RPO MJ8) removal and installation procedures (SI Document ID #1277169) in the 2004, 2005, or 2006 Saturn VUE Service Manual.

SHIPPING PREPARATION

1. Place removed AWD transfer case (RPO MJ8) core into the original shipping container. Ensure that all the oil is properly drained from the core and the drain plugs are replaced.
2. Complete and attach the core tag to AWD transfer case (RPO MJ8) the core.
3. Place the drained AWD transfer case (RPO MJ8) core into the provided plastic bag, and then carefully place the bagged AWD transfer case (RPO MJ8) core in the shipping container.
4. Secure the AWD transfer case (RPO MJ8) core to the shipping container as received in the original packaging.
5. Return the AWD transfer case (RPO MJ8) core as soon as possible to the SSPO Core Return Center in Spring Hill, TN (in Canada, use the normal core return process to return to your servicing PDC).

Important: NO credit will be provided for incorrect, incomplete, or disassembled AWD transfer case (RPO MJ8) cores. AWD transfer case (RPO MJ8) damage caused as the result of collision, fire, flood, or misuse is not eligible to participate in this program.

SHIPPING INSTRUCTIONS

1. Core returns are to be shipped to the SSPO Core Return Center in Spring Hill, TN (in Canada, use the normal core return process to return to your servicing PDC) upon completion of repair. U.S. retailers, Please refer to "Special Transactions" in the Saturn Parts Policies and Procedures Manual for core return process information.
2. Using the Core Return Tag (item # S0399300), completely fill in the following information: the core part number, retailer code, CSO number, and the last eight (8) digits of the vehicle identification number (VIN). Retailers will NOT receive credit for returned cores if the Core Return Tag has not been completed.

The following labor operations are to be used for the limited service on the Transfer Case, RPO MJ8. For labor time information, refer to the Saturn Electronic Labor Time Guide.