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Matt Gibson's Saturn Vue All Wheel Drive CVT Transmission Created on April 20, 2011 using FlipShare.

Here’s a detailed guide on how to repair the gearbox output flange on a Saturn Vue, presented with bullet points for clarity.

### Tools and materials Needed:
– **Socket Set**: A complete set of sockets (metric and standard) with ratchet and extensions to remove bolts.
– **Wrench Set**: A combination of open-end and box-end wrenches to access tight spaces.
– **Torque Wrench**: To ensure bolts are tightened to manufacturer specifications.
– **Jack and Jack Stands**: For safely lifting the vehicle to access the undercarriage.
– **Pry Bar**: For removing the output flange and any stuck components.
– **Seal Puller**: To help remove the old output seal without damaging surrounding components.
– **Gasket Scraper**: To clean the surface where the new flange will be installed.
– **Shop Towels**: For cleaning and wiping surfaces during the repair.
– **Gear Oil**: To refill the gearbox after the repair.
– **New Output Flange**: Ensure you have the correct part that matches your vehicle.
– **New Output Seal**: A fresh seal to prevent leaks after the installation of the new flange.

### Preparation:
– **Safety First**: Wear safety glasses and gloves throughout the repair process.
– **Disconnect the Battery**: Prevent any electrical issues by disconnecting the negative terminal of the battery.
– **Lift the Vehicle**: Use a jack to lift the car and place it on jack stands for stability.

### Removal of the Old Output Flange:
– **Access the Gearbox**: Locate the gearbox output flange under the vehicle.
– **Remove Bolts**: Using the socket set, remove any bolts securing the output flange to the gearbox. Keep these bolts in a safe place for reinstallation.
– **Inspect for Damage**: Check the condition of the old flange and the surrounding area for any additional damage.
– **Use Pry Bar**: If the flange is stuck, gently use a pry bar to loosen it from the gearbox. Be careful not to damage the gearbox casing.
– **Remove the Old Seal**: Use the seal puller to carefully extract the old output seal from the gearbox housing.

### Cleaning and Preparation:
– **Clean the Flange Area**: Use the gasket scraper to clean any remnants of the old seal or gasket from the gearbox surface. Ensure it’s smooth and free of debris.
– **Inspect Gearbox**: Look for any signs of wear or damage on the gearbox itself, as this may require additional repair.

### Installation of the New Output Flange:
– **Install New Output Seal**: Carefully press the new output seal into the gearbox housing. Ensure it sits flush and is seated properly.
– **Position New Flange**: Align the new output flange with the gearbox output shaft and gently push it into place.
– **Secure with Bolts**: Reinstall the bolts that were removed earlier, using the socket set. Tighten them in a crisscross pattern to ensure even pressure.
– **Torque to Specification**: Use the torque wrench to tighten the bolts to the manufacturer’s specified torque settings.

### Final Steps:
– **Refill Gear Oil**: Check the gearbox oil level and refill if necessary, ensuring it meets the recommended specifications for your Saturn Vue.
– **Reconnect the Battery**: Reattach the negative battery terminal.
– **Lower the Vehicle**: Carefully remove the jack stands and lower the vehicle back to the ground.
– **Test Drive**: Take the vehicle for a short test drive to ensure everything is functioning correctly and listen for any unusual noises.

### Post-Repair Inspection:
– **Check for Leaks**: After the test drive, inspect the area around the output flange for any signs of leaking fluid.
– **Monitor Performance**: Over the next few days, monitor the gearbox performance for any irregularities.

By following these steps and using the appropriate tools, you should be able to successfully repair the gearbox output flange on your Saturn Vue. Always consult your vehicle’s repair manual for specific details related to your model.
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