2003 Saturn Vue Hot smell after 6 hour trip

2003 SATURN VUE
150,000 MILES • 4 CYL • AWD • AUTOMATIC
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SHANDIES
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Drove from Portland, Oregon to Coeur d Alene Idaho, started smelling "something" around Spokane (last leg of 6 hour trip) smelled like insecticide (to me). When I stopped at destination I discovered the smell was from my car. the engine was "warm" therm needle was approaching mid mark, no lights came on, no steam, no surging just a hot smell and that weird insecticide odor, after turning off the engine. Vue was not bearing any load weight. I had made this trip to tow a haul trailer to Southern Oregon: towing cap 1,500#. Too, there has been a "sound" that I am not familiar with, vehicle is new to me, thought it to be the transmission belts, I dunno?? Help!
Oct 18, 2015 at 9:32 AM
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SATURNTECH9
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Is the noise present at slow speeds 5-10mph?
Oct 18, 2015 at 5:12 PM
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SHANDIES
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I took my VUE to Oil Can Henry's to check fluid levels, they discovered a crack in my differential transfer case (see photo) due to over tightening during service 8/14/2015 the heat of the road trip most likely expanded the crack to the point of leakage. They did a temp fix and stated they were liable and would take responsibility for the cost of replacement. So no towing until this is fixed.

As far as the sound goes, yes it's there at 5-10 MGH the vehicle is noisy; any ideas?

Thank you
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Oct 19, 2015 at 5:55 AM
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SATURNTECH9
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So was the fluid completely empty or really low?Maybe thats your noise?So is the fluid leaking from the rear drive module or the power take off unit bolted to the transmission?Is the noise coming from the front or rear?
Oct 20, 2015 at 6:49 PM
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SHANDIES
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I can't tell where the noise is coming from. most likely from the rear. OCH said at time of service in 'aug that the differential fluid needed to be changed but didn't comment on any cracks or it being low.

Now the crack is so bad the fluid levels are dangerously low and I am not able to drive the car until the T-case is replaced...
Oct 21, 2015 at 1:49 PM
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SATURNTECH9
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So its the rear drive module leaking in the rear?If so thats probably your noise and it will most likely need the case and a clutch pack assembly that was damaged by the low fluid.
Oct 21, 2015 at 7:22 PM