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replace a axle seal on saturn ion

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FORD: LINCOLN: 2002-2006 Explorer 2003-2005 Aviator 2003-2006 Expedition 2003-2006 Navigator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 05-15-5 to update the 3. Do not use a damaged seal installation tool vehicle model years, Parts, and Service Procedure. exhibiting nicks, burrs, or sharp edges. NOTE ISSUE THE USE OF SEAL PROTECTOR 1L2W-4N206-AA Some 2003-2006 Expedition/Navigator, 2002-2006 IS NO LONGER REQUIRED. Explorer 4dr/Mountaineer, and 2003-2005 Aviator vehicles equipped with the 8.8? or 9.75? ring gear 4. Do not tap directly on the back of the seal and independent rear suspension (IRS), may exhibit installation tool, always tap on the handle, per leaks at the rear halfshaft axle seals. A new Instruction Sheet. Seal should be driven evenly unitized seal is now available for service. The new into housing bore with only enough force to seal design eliminates the need to use seal seat in the bore. protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is 5. Before installing the halfshaft, verify that the required. inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is ACTION present, follow the kit Instruction Sheet and Order and install the new seal kit to correct the leak remove the excluder seal. condition. Review the updated instruction sheet NOTE included in the kit and obtain the required tools before beginning repair. OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. INSTALLATION SERVICE TIPS PART NUMBER PART NAME Refer to the appropriate Workshop Manual, Section 7L1Z-4A109-B Axle Shaft Seal Kit (9.75 Axle) 205-02 for half shaft removal and installation. 7L1Z-4A109-C Axle Shaft Seal Kit (8.8 Axle) NOTE IN THE WORKSHOP MANUAL UNDER THE HALF WARRANTY STATUS: Eligible Under Provisions Of SHAFT REMOVAL/INSTALLATION SECTION New Vehicle Limited THERE ARE ADDITIONAL PARTS CALLED OUT Warranty Coverage THAT ARE REQUIRED TO BE REPLACED. OPERATION DESCRIPTION TIME THESE PARTS ARE NOT INCLUDED IN THE 062205A 2003-2006 0.8 Hr. AXLE SHAFT SEAL KIT LISTED. Expedition/Navigator: Replace Rear Axle (Stub) 1. Use only the proper seal installation tool, Lisle Shaft Seal Includes Time Special Seal Installer (LIS 17850) available To Remove And Install through the Rotunda Technician Tool Program. Halfshaft One Side (Do Not Use With 4139A, 2. Ensure the seal installation tool is clean and 4139A2) free of debris prior to inserting into new seal.

4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0500, P0836, P1875 Set (Replace Encoder Motor Sensor, Reprogram TCCM, Inspect Front Drive Axle Engagement Sleeve for Damage/Repair if Necessary)

Correction Important: For ease of reassembly, shift the transfer case assembly to 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8) prior to removing any components. For information on placing the NV246 (NP8) transfer case in NEUTRAL, see the procedure at the end of this bulletin. 1. Remove the transfer case and front axle/engine skid plates (if equipped). 2. Disconnect and position the front propeller shaft aside. 3. Disconnect the transfer case encoder motor wiring harness. 4. Remove the three (3) bolts that retain the encoder motor to the transfer case. 5. Separate the encoder motor assembly from the transfer case and place it on a work bench. Important: DO NOT REMOVE THE SCREWS INDICATED WITH THE (1) IN THE ABOVE ILLUSTRATION. 6. Remove the four screws on the outer perimeter of the encoder motor housing. Important: For proper timing and ease of reassembly, hold the gear in place as your remove the cover from the encoder motor assembly with your thumb or finger. 7. Carefully remove the cover from the encoder motor assembly. The cover has a seal on the bottom side. Place the cover in a position to protect this seal from damage and/or contamination. Important: Observe the location of the punch mark on the large gear in relation to the timing mark on the housing if the transfer case was placed in the 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8). The timing marks should be within one tooth of proper alignment. If not, you must note the timing mark positions for reassembly. 8. Locate the two shims; one on the small gear and another on the larger gear. Set them aside on a clean surface for reuse. Important: After removing the large gear from the housing, a dark gray phenolic spacer should remain in the casting where the bottom of the large gear resides. Locate this spacer and save for reuse. 9. Carefully lift the large gear from the housing. The sensor and wiring harness will come with the gear. 10. Disconnect the wiring from the sensor. 11. Separate the sensor from the large gear.


REMOVAL & INSTALLATION FWD AXLE SHAFT Removal (Axle Shaft) 1. Raise and support vehicle. Remove front wheel assembly. Remove wheel bearing lock nut. Remove brake caliper, and support aside. Remove brake rotor. 2. Disconnect tie rod end. Remove upper knuckle nut, and separate knuckle assembly from third link assembly. Push axle shaft through hub, and separate axle assembly from knuckle assembly. 3. Insert screwdriver blade between transaxle case and right axle inner CV joint. Pry out on joint until joint pops free. Use care not to damage axle boot or axle seal. 4. On M/T vehicles, remove left axle in same manner. On A/T vehicles, insert screwdriver through differential, and drive axle out of transaxle case using a hammer. See Fig. 2 . PROBLEM Possible Cause/Action GREASE LEAKING Ripped CV Boot Replace Boot CLICKING NOISE WHILE CORNERING Dry/Worn CV Joints Replace Outer CV Joints CLUNK ON ACCELERATION Dry/Worn CV Joints Replace Inner CV Joints Worn Transmission Gears/Bearings Inspect Transmission VIBRATION/SHUDDER ON ACCELERATION Dry/Worn CV Joints Replace CV Joints Alignment Out Check Alignment Incorrect Spring Height Check Spring Height SQUEALING OR HUMMING Dry/Worn CV Joints Lube/Replace CV Joints Faulty Wheel Bearing Replace Wheel Bearing NOTE: DO NOT allow brake caliper to hang from brake hose. CAUTION: Use care not to damage pinion mate shaft or side gear while driving out axle. 1991 Infiniti G20 AXLE SHAFTS – FRONT’ ’1991-92 DRIVE AXLES FWD Axle Shafts None Page 2
Fig. 2: Removing Left Drive Axle (A/T Vehicles) Courtesy of NISSAN MOTOR CO., U.S.A. Removal (Outer CV Joint) 1. Remove and discard boot bands. Slide boot off joint housing. Thread wheel bearing lock nut onto joint. Using a slide hammer and bearing puller, remove joint from axle shaft. See Fig. 3 . NOTE: Outer joint cannot be disassembled. Remove and inspect joint and replace if damaged or worn. 1991 Infiniti G20 AXLE SHAFTS – FRONT’ ’1991-92 DRIVE AXLES FWD Axle Shafts None Page 3 2. Remove circlip from end of axle, and remove boot. If boot is being reused, take care not to cut boot on axle splines during removal. Clean CV joint in suitable solvent. Inspect components, and replace joint if necessary.

4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal)4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Transmission Repair

Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: Subject: 4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer Models 2003-2005 GMC Envoy Models 2003-2004 Oldsmobile Bravada 2005 Saab 9-7X with 4.2L In-Line 6 Cylinder Engine (VIN S — RPO LL8) • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. • Remove the surge tank cap and examine the coolant for signs of contamination with transmission fluid (the coolant will have a milky, not clear appearance). • If the coolant has a normal, clear appearance, the radiator should not be replaced. • The cooler can also be tested by following the Coolant System Leak Test procedure (SI Document ID# 877442). Do NOT replace a radiator without verifying that the transmission oil cooler is leaking. If water or coolant is found in the transmission, the following components MUST be replaced. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube. 3. Remove the filler tube nut (2) located on the right side of the engine. 4. Remove the filler tube from the vehicle. Tip It is necessary to remove the two A/C line (suction line / low side of muffler hose) retainers and reposition • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow .
the A/C line to allow proper clearance for installation of the new transmission fluid fill tube. 5. Remove the A/C line at the oil level indicator tube bracket nut. 6. Remove the A/C bracket bolt from the engine lift hook. 7. Reposition the A/C line upward. 8. Install the new transmission filler tube, P/N 15000220, into position but NOT into the transmission at this time. 9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID# 744862). 10. Remove the two bolts securing the transmission heat shield to the transmission. 11. Remove the transmission heat shield from the transmission. 12. Remove the old filler tube seal from the transmission case. 13. Install a new seal, P/N 1259475 into the transmission case. 14. Position the new transmission filler tube into the transmission seal. 15. Install the transmission heat shield to the transmission. 16. Install the two bolts securing the transmission heat shield to the transmission. Tighten Tighten the bolts to 17 N·m (13 lb ft). 17. Lower the vehicle. 18. Install the nut securing the filler tube to the stud. Tighten Tighten the nut to 10 N·m (89 lb in). 19. Reposition the A/C line into place. 20. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. 21. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt

4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).