Transfer Case Disassemble. Saturn OUTLOOK

For 1990-2009 cars only

Makes 🢒 Saturn 🢒 2008 🢒 OUTLOOK - FWD 🢒 Transmission/Transaxle 🢒 Transfer Case - Getrag 790 🢒 Transfer Case Disassemble

Table 1:	Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Table 2:	Intermediate Drive Shaft Removal
Table 3:	Rear Output Shaft Housing Removal
Table 4:	Right Transfer Case, Input and Output Drive Shaft Removal
Table 5:	Rear Output Shaft Housing Disassembly
Table 6:	Intermediate Drive Shaft Disassembly

Callout	Component Name
1	Transfer Case O-Ring Seal
2	Transfer Case Vent Assembly Tip Remove the vent only if damaged or blocked.
3	Transfer Case Heat Shield Bolt (Qty: 3) Tip After removal, the optional heat shield does not need to be installed. Refer to Transfer Case Description and Operation.
4	Transfer Case Heat Shield Tip After removal, the optional heat shield does not need to be installed. Refer to Transfer Case Description and Operation.
5	Transfer Case Drain Plug
6	Transfer Case Fill Plug

Callout	Component Name
1	Front Wheel Drive Retainer
2	Front Wheel Drive Intermediate Shaft Special Tools J 25070 Heat Gun - 500-750F

Callout

Component Name

Front Wheel Drive Retainer

Front Wheel Drive Intermediate Shaft

J 25070 Heat Gun - 500-750F

Callout	Component Name
1	Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2	Transfer Case Rear Output Shaft Housing Tip Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal. Special Tools J 25070 Heat Gun - 500-750F
3	Transfer Case Rear Output Shim
4	Transfer Case Rear Output Shaft Housing Seal O-Ring Tip Discard the O-ring after removal.

Callout

Component Name

Transfer Case Half Bolt (Qty: 11)

Transfer Case - Right

Transfer Case Seal

Transfer Case Input Shaft

Transfer Case Rear Output Drive Shaft

Transfer Case Half Locating Pin (Qty: 2)

Tip

•	Remove the pins only if damaged.

•	Inspect the case for similar damage.

Callout	Component Name
1	Transfer Case Rear Output Shaft Gear Nut Tip Use a 30 mm socket or J 29873 . Special Tools J-08614-A Pinion Flange Holder and Remover
2	Transfer Case Rear Output Shaft Flange Special Tools DT-48145 Press Support
3	Transfer Case Rear Output Shaft Bearing Assembly Tip Use a press to remove the output shaft from the housing.
4	Transfer Case Rear Output Shaft Bearing Spacer
5	Transfer Case Rear Output Shaft
6	Transfer Case Rear Output Shaft Oil Slinger Refer to Rear Output Drive Housing Cleaning and Inspection. Tip Remove the slinger only if damaged.
7	Transfer Case Rear Output Shaft Seal Tip Discard the seal after removal.

Callout	Component Name
1	Half Shaft Retainer
2	O-Ring
3	Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
4	Front Wheel Drive Intermediate Shaft Bearing Assembly Tip Use a press, with the J 22912-B flat side up, in order to remove the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover