Moan/Grown Noise/Vibration from Rear of Vehicle when Turning at Low Speeds (Replace Rear Drive Module Differential Clutch Drum)
| Subject: | Moan/Growl Noise/Vibration from Rear of Vehicle when Turning at Low Speeds (Replace Rear Drive Module Differential Clutch Drum) |
| Models: | 2003-2004 Saturn VUE Vehicles with All Wheel Drive (AWD) |
| Attention: | Technician |
This bulletin is being revised to update the part number information and add an important statement and sealing procedure. Please discard Corporate Bulletin Number 03-04-20-003A (Section 04 -- Driveline/Axle).
Important: This bulletin does NOT apply to 2004 Saturn VUE vehicles with 3.5L V-6 (L66) engines and AWD built between and including VIN breakpoint 4S800001-4S892254. For vehicles with 3.5L V-6 (L66) and AWD within this VIN range, refer to Customer Satisfaction Program 04090.
Condition:
Some customers may comment on a moan, growl noise, or vibration coming from the rear of the vehicle when turning at low speeds (such as parking lot maneuvers). Saturn VUE vehicles equipped with a VTi transmission (RPO M16) may also make clunking/rattle noises from the front transaxle area during the same driving conditions.
Cause:
Water contamination of the differential clutch plates in the rear drive module (RDM) may cause the clutch plates to chatter on turns.
Correction:
Replace the differential clutch drum in the RDM and replace RDM filter. On vehicles produced prior to VIN 3S849825, install a vent cap on the RDM vent hose to prevent water intrusion. Follow the "Differential Clutch Drum Assembly Replacement" procedure in the Driveline/Axle section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1347583) to perform this repair with the RDM in the vehicle.
Diagnostic Procedure:
- Test drive vehicle to confirm customer comment.
- Remove propshaft and test drive vehicle under same conditions.
| • | If noise is gone, replace RDM differential clutch drum and RDM filter using the "Differential Clutch Drum Assembly Replacement" procedure in the Driveline/Axle section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #1347583). This procedure also applies to 2003 model year vehicles. On vehicles produced prior to VIN 3S849825, install a vent cap, P/N 03820840, on the RDM vent hose to prevent water intrusion. |
| • | If noise remains, refer to the 2003 Saturn VUE Chassis Service Manual for diagnosis of rear suspension noises, or the 2003 Saturn VUE Transaxle Service Manual for diagnosis of transaxle noises. For 2004 vehicles, refer to the Suspension section of the 2004 Saturn VUE Service Manual, Vol. 1 for diagnosis of rear suspension noises, or the Transmission/Transaxle section of the 2004 Saturn VUE Service Manual, Vol. 2 for diagnosis of transaxle noises. |
Sealing Procedure:
- Thoroughly clean the sealing surfaces with brake clean, or equivalent, and allow the surfaces to dry.
- Use one of the RTV sealants from the chart in this bulletin. Apply a continuous bead of sealant 2.5 mm (0.098 in) in diameter to the sealing surface of the differential housing.
Notice: Do not use excessive amounts of sealant. Excess sealant could plug the vent passage, enter the oil pump, and/or the oil pump screen causing component failure.
Important: Ensure sealing surface is clean and oil free.
Parts Requirements:
Important: Use the correct part for the application. The 2004 VUE with the 3.5L V-6 (L66/MJ8) has a unique differential clutch drum.
Important: Allow Permatex® Right Stuff/Loctite® 5900 sealant to skin for 5 minutes before assembly.
Part Number | Description | Qty |
|---|---|---|
15235312 | Differential Clutch Drum 2004 4-cyl (L61/M16) 2002-03 All | 1 |
15235314 | Differential Clutch Drum 2004 3.5L V-6 (L66/MJ8) | 1 |
12569934 | Differential Oil Filter | 1 |
03820840 | Vent Hose Cap | 1 |
12569951 | Differential Pinion Gear Nut | 1 |
12378514 Canada P/N 88901045 | Rear Axle Lubricant (GM Versatrak® Fluid | 1.5 bottles |
Saturn P/N 21005994 Canada P/N 12345493 | Loctite® Threadlocker 262 or Permatex 27200 | $5.85 per vehicle* Billed as Net Item "M" |
Saturn P/N 21019581 GM P/N 12346286 Canada P/N 10953472 | Permatex® Right Stuff/Loctite® 5900 | $1.65 Per vehicle** Billed as Net Item "M" |
21485278 Canada P/N 10953480 | Loctite® Threadlocker 592 | $2.09 per vehicle*** Billed as Net Item "M" |
All material prices are retailer cost plus 40%
*1 tube will service 3 vehicles. One tube $17.56 / 3 vehicles = $5.85 per vehicle.
**1 tube will service 10 vehicles. One tube $16.53 / 10 vehicles = $1.65 per vehicle.
*** 1 tube will service 10 vehicles. One tube $20.86 / 10 vehicles = $2.09 per vehicle.
Total Material Allowance is $9.59 per vehicle.
Claim Information:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for F2240 (Plates or Drum, Limited Slip Differential - Replace).
Claiming Loctite® Threadlocker 592, Loctite® Threadlocker 262, and Sealant - Right Stuff
It will be necessary to sell these materials to the CSO as "material" using net item code "M" per the Parts Information chart in this bulletin. Claims received in the amount of $9.59 will be accepted. Claims exceeding the amount of $9.59 will be returned with Return Reason 143 - material/reimbursement > maximum allowed.
