Saturn 23245651 Power Transfer U Case Assembly

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Loosen the right front wheel lug nuts and driveaxle/hub nut. Raise the vehicle and support it securely on jackstands. Remove the wheel. Drain the transfer case lubricant. Drain the transaxle fluid. Remove the driveshaft. Remove the right driveaxle. Disconnect the front flexible exhaust pipe at both front and rear catalytic converters and the muffler pipe and remove the front portion of the exhaust system. Support the rear exhaust pipe with wire. Support the transaxle with a jack, jackstand or equivalent. Remove the right-side (rear) engine mount. If equipped, disconnect the active engine mount vacuum line before removing the rear engine mount. Remove the rear engine mount bracket bolts and remove the bracket from the engine. Remove the transfer case mounting bolts. Disconnect the intermediate shaft by pulling the transfer case away from the transaxle, and remove the transfer case. Installation is the reverse of removal, noting the following points: Install a new 0-ring seal between the transfer case and transaxle. Use two guide pins during installation of the transfer case to the transmission. Failure to do so may result in damage to the 0-ring seal, causing a fluid leak. Guide pins can be made by cutting the heads off of 2 M12x1.75x75 bolts. Hand thread the guide pins into the upper and lower transfer case mounting bolt holes. Once the transfer case is installed, remove the guide pins and install the mounting bolts. Tighten the exhaust system fasteners. Tighten the driveshaft fasteners. Tighten the transfer case mounting bolts. Refill the transfer case and transaxle with the proper type and amount of lubricant. Tighten the driveaxle/hub nut. Tighten the wheel lug nuts.