Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSATURN2005RELAY AWDREPAIR AND DIAGNOSISTRANSMISSIONTRANSFER CASETRANSFER CASE - OVERHAUL - STEYRSPECIFICATIONSGENERAL SPECIFICATIONS
2005 Saturn Relay AWD
General Specifications
2005 Saturn Relay AWDSECTION General Specifications
General Specifications
| Application | Specification | |
|---|---|---|
| Metric | English | |
| Differential Bearing Preload | 0.1-0.15 mm | 0.004-0.006 in |
| Differential Carrier Rotating Torque | 1.5 N.m | 13 lb in |
| Drive and Drivenshafts Gears Backlash | 0.2-0.3 mm | 0.0078-0.0118 in |
| Drivenshaft Rotating Torque | 1.5 N.m | 13 lb in |
| Driveshaft Bearing Preload | 0.15 mm | 0.006 in |
| Driveshaft Rotating Torque | 1.5 N.m | 13 lb in |
| Extension Housing Gear Oil Fill Quantity | 290 ml | 9.80 oz |
| Gear Ratio Front-to-Rear | 1.013:1 | |
| Idler Gear Bearing Preload | 1.02-1.78 mm | 0.004-0.007 in |
Extension Housing Shim Calculation Table - Procedure A
| Calculation | Comment | Metric | English |
|---|---|---|---|
| Actual Measurements | |||
| A | A = Nominal or "Given" Value | 57 mm | 2.24 in |
| -B | Subtract B = Pinion Thickness | ||
| +C | Add C = Pinion Installed Height | ||
| -D | Subtract D = Driveshaft Housing Calculated Value | ||
| +/- | Add or Subtract the Plus, Minus, or Zero Value Etched on the End of the Driveshaft | ||
| = Extension Housing Shim Thickness | |||
Extension Housing Shim Calculation Table - Procedure B
| Calculation | Comment | Metric | English |
|---|---|---|---|
| Actual Measurements | |||
| C | Pinion Installed Height | ||
| +E | Add E = Measured Value on the End of the Drivenshaft | ||
| F | C plus E equals F, the Pinion Calculated Height | ||
| D | Driveshaft Housing Calculated Value | ||
| -F | D minus F equals the Extension Housing Shim Thickness | ||
| = Extension Housing Shim Thickness | |||
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.