GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 VUE - AWD 🢒 Engine 🢒 Engine Electrical 🢒 Transfer Case Replacement

Tools Required

    • J 44017 Shaft Remover
    • SA9133T Slide Hammer

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the intermediate drive shaft. Refer to Intermediate Shaft Replacement in Wheel Drive Shafts.

    3. Object Number: 928957 Size: SH

    Important: Remove the retainer ring from the stub shaft for tool installation. Discard the used retainer ring.

    Important: Use the proper container for fluid loss when the stub shaft is removed. Plug power take-off unit (PTU) to minimize fluid loss.

  3. Disengage the PTU stub shaft from the PTU using the J 44017 and SA9133T .

    4. Object Number: 928924 Size: SH
  4. Remove the propshaft center bearing to underbody bolts.

    5. Object Number: 928930 Size: SH

    Important: Index mark the propshaft to PTU for re-installation.

  5. Remove the front propshaft attachment bolts.
  6. Compress the CV joint and disengage the propshaft from the PTU and secure with wire.

    7. Object Number: 928975 Size: SH
  7. Separate the steering gear from the cradle for clearance. Refer to Steering Gear Replacement .

    8. Object Number: 928677 Size: SH
  8. Remove the rear powertrain mount bracket bolts from the PTU.

    9. Object Number: 928962 Size: SH
  9. Remove the PTU brace bolts and remove the brace.

    10. Object Number: 928984 Size: SH
  10. Remove the PTU to transmission bolts.
  11. Remove the PTU vent hose.

Installation Procedure

    Object Number: 928984 Size: SH

    Important: Lubricate the seal with transmission fluid prior to PTU installation.

  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. Object Number: 928962 Size: SH
  3. Install the PTU brace. Hand start all 6 bolts.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Tighten the PTU to transmission bolts.

    5. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  5. Tighten the PTU brace bolts.

    6. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).


    Object Number: 928677 Size: SH
  6. Hand start all the powertrain mount to PTU bolts and tighten.

    7. Object Number: 928930 Size: SH

    Important: Use the index mark for reassembly.

  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. Important: Apply Permatex Threadlocker®-Blue to bolt threads.

  9. Hand start all propshaft coupling bolts and tighten.

    10. Tighten
    Tighten the bolts to 25 N·m (19 lb ft).


    Object Number: 928924 Size: SH
  10. Install the center bearing bolts.

    11. Tighten
    Tighten the bolts to 25 N·m (19 lb ft).

  11. Install the intermediate drive shaft. Refer to Intermediate Shaft Replacement in Wheel Drive Shafts.
  12. Position the steering gear mounts to the cradle. Refer to Steering Gear Replacement .
  13. Install the PTU vent hose.

    14. Object Number: 737270 Size: SH

    Important: Use sealant GM P/N 12345493 or equivalent on fill plug.

  14. Check the PTU fluid fill. Remove the fluid fill plug. Fill until fluid is just below the bottom of the fill hole.

    15. 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 in Automatic Transmission - VT25-E.