Differential Clutch Drum Assembly Replacement
Differential Clutch Drum Assembly Replacement- Tools Required
- J 44873 Pinion Flange Holder and Remover
- J 46607 Alignment Tool
Removal Procedure
1. Raise and support the vehicle.
2. Remove the propeller shaft underbody guard loop bolts.
3. Remove the guard loop.
4. Reference mark the propeller shaft flange-to-pinion flange relationship at the rear drive module (RDM).
5. Remove the propeller shaft flange mounting bolts at the RDM pinion flange.
6. Position the end of the propeller shaft away from the RDM and secure with heavy mechanics wire, or equivalent.
7. Place a container under the RDM housing.
8. Remove the RDM drain plug.
9. Drain the RDM fluid.
10. Install the J 44873 (1) to the pinion flange (2).
11. Using a breaker bar to hold the J 44873 stationary, loosen the pinion flange nut.
12. Remove and discard the pinion flange nut (1).
13. Remove the pinion flange (2).
14. Remove the RDM housing cover bolts (1).
15. Carefully remove the housing cover (2) from the RDM.
16. Remove the clutch drum (2) from the housing cover (1).
17. Remove the filter assembly.
18. Remove the locating pins.
Important: Do not gouge the housing cover and RDM sealing surfaces.
19. Remove all traces of sealer from the housing cover and RDM sealing surfaces.
20. Clean the housing cover and RDM sealing surfaces with denatured alcohol or equivalent, and dry with a clean, lint free cloth.
21. Check the pinion flange sealing surface (1) for wear or gouges, the bolt threads (2) for damage and the pinion splines (3) for worn or damaged splines.
22. Inspect the dust deflector (2) for cracks.
23. Inspect the pinion flange seal (1), the front seal (2) and the rear seal (3) for tears, cuts, and gouges on the seals and sealing surfaces.
Installation Procedure
1. Install a new filter assembly.
2. Install the locating pins.
3. Align the clutch with the pump and pump bushing. Place the J 46607 in the splines of the clutch. Twist alignment tool back and forth to align the pump and bushing. With a properly aligned clutch, the grove on the J 46607 will be flush with the drum as shown. Remove the tool by pulling straight out.
Notice: Do not submerge the clutch drum in solvent. This will damage friction material and geroter pump.
4. Install the clutch drum (1) to the pinion shaft (2) by shaking the drum while rotating the drum back and forth to engage the splines of the pump rotor and bushing.
5. When properly engaged, the clutch drum will be fully seated against the clutch drum oil seal (1).
6. Apply a continuous bead of sealer Saturn P/N 12346240 of equal height and width to the RDM housing sealing surface.
Specification
- Apply sealer to a height and width of 2.5 mm (0.098 inch).
Notice: The clutch cover housing must be fully seated to the rear drive module (RDM). Do Not use the mounting bolts to draw the cover to the RDM. If the cover does not fully seat to the RDM, the clutch drum assembly splines must be realigned to the pinion shaft splines before proceeding. Failure to follow these instructions will result in damage to the clutch assembly.
Important: Do not disturb the sealer bead applied to the RDM sealing surface.
7. Install the clutch housing cover (1) to the RDM.
Notice: Refer to Fastener Notice in Cautions and Notices.
8. Hand install the clutch housing cover bolts (2).
- Tighten the bolts to 26 Nm (19 ft. lbs.).
Important: Strict adherence to the sealer cure time must be observed.
9. Allow the sealer to cure a minimum of 8 hours.
10. Install the dust deflector (2) to the input flange (1) if removed.
11. Install the input flange (2) to the clutch shaft.
12. Hand install a new input flange nut (1) to the clutch shaft.
13. Install the J 44873 (1) to the pinion flange (2).
14. Using a breaker bar to hold the J 44873 stationary, tighten the pinion nut.
- Tighten the nut to 203 Nm (150 ft. lbs.).
15. Thoroughly clean the drain plug threads and apply thread sealer Saturn P/N 21485278 to the plug threads.
16. Install the RDM drain plug.
- Tighten the plug to 30 Nm (22 ft. lbs.).
17. Remove the RDM fill plug.
18. Thoroughly clean the fill plug threads and apply thread sealer Saturn P/N 21485278 to the plug threads.
19. Fill the RDM with lubricant.
20. Install the fill plug.
- Tighten the plug to 35 Nm (26 ft. lbs.).
21. Thoroughly clean and apply thread-locker Saturn P/N 21005994 to the propeller shaft flange mounting bolt threads.
22. Align the reference marks on the propeller shaft flange and the RDM input flange.
23. Install the propeller shaft flange mounting bolts.
- Tighten the bolts to 50 Nm (37 ft. lbs.).
24. Install the propeller shaft underbody guard loop.
25. Install the propeller shaft underbody guard loop bolts.
- Tighten the bolts to 24 Nm (18 ft. lbs.).
26. Lower the vehicle.