Fluid Leak at Rear Axle (Replace Left Differential Side Cover O-Ring and Left Axle Shaft Seal, Add Sealant to Side Cover Flange)

This bulletin is being revised to add the 2005 model year and provide VIN breakpoints. Please discard Corporate Bulletin Number 03-04-20-006 (Section 04 -- Driveline/Axle).

Built Prior to the Following VIN Breakpoints:

Some customers may comment on fluid leaking from the rear axle.

Verify that the fluid leak is rear axle fluid, not transmission fluid. Replace the left differential side cover O-ring and left axle shaft seal. Engineering has recommended that sealant be applied to the side cover prior to installation. Use the appropriate service procedure and part numbers listed below.

1. Raise and support the vehicle.
2. Remove the rear tire and wheel assemblies.
3. Install J 33432-A Transverse Spring Compressor to the rear transverse spring and compress the spring.
4. Disconnect the electrical connectors from both wheel speed sensors.
5. Disconnect the electronic suspension control (ESC) position sensor links, if equipped.
6. Disconnect the shock absorber solenoid electrical connectors, if equipped.
7. Remove the brake calipers from the caliper mounting brackets and support aside.
8. Remove the outer tie rod end nuts.
9. Disconnect the outer tie rod end studs from the rear suspension knuckles.
10. Disconnect the park brake cables from the park brake apply levers and brackets.
11. Remove the shock absorber lower mounting bolts from the lower control arms.
12. Remove the bolts securing the upper control arms to the frame.
13. Remove the spindle nuts retaining the rear wheel axle shafts to the hubs.
14. Rotate the suspension knuckles until the axle shafts clear the hubs.
15. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
16. Release brake pipes from underbody clips.
17. Remove the transaxle mount to rear crossmember nuts.
18. Position an adjustable jack stand under the transmission and support the transmission.
19. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
20. Remove the rear suspension crossmember mounting nuts.
21. Slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
22. Release and remove the rear wheel axle shafts from the differential.
23. Remove the intermediate exhaust pipe.
24. Remove the left muffler.
25. Drain the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual.
26. Remove the left differential mount.
27. Clean any dirt or debris from around the differential cover.
28. Remove the bolts retaining the differential cover.
29. Remove the differential cover from the differential.
30. Remove and discard the O-ring seal and the axle seal from the differential cover.
31. Clean the O-ring sealing surface on the differential cover and the differential housing.
32. Install new O-ring, P/N 89047953, to the differential cover.
33. Apply a continuous 3 mm (0.125 in) bead of sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the cover flange.
34. Apply sealant around the bolt holes. Keep sealant away from the O-ring.
35. Install the differential cover to the differential.
36. Install the differential cover retaining bolts.

Tighten
Tighten the bolts to 28 N·m(20 lb ft).

37. Clean the excess sealant from the left cover/housing splitline.
38. Install the new axle seal, P/N 88996703, into the differential cover using J 46405.
39. Install the left differential mount.
40. Install the left muffler.
41. Install the intermediate exhaust pipe.
42. Install the rear wheel axle shafts to the differential.
43. Install the rear suspension crossmember.

•	Align the crossmember dowel pins to the holes in the frame rails.

•	Align the transaxle mount studs to the crossmember.

44. Install the rear suspension crossmember mounting nuts.

Tighten
Tighten the crossmember mounting nuts to 110 N·m(81 lb ft).

45. Remove the transmission jack from the crossmember.
46. Remove the adjustable jack stand from under the transmission.
47. Install the transaxle mount to rear crossmember nuts.

Tighten
Tighten the transaxle mount nuts to 50 N·m(37 lb ft).

48. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
49. Install the brake pipes to the underbody clips.
50. Install the spindle nuts retaining the rear wheel axle shafts to the hubs.

Tighten
Tighten the spindle nuts to 160 N·m(118 lb ft).

51. Install the bolts securing the upper control arms to the frame.

Tighten
Tighten the upper control arm bolts to 110 N·m(81 lb ft).

52. Install the shock absorber lower mounting bolts to the lower control arms.

Tighten
Tighten the shock absorber lower mounting bolts to 220 N·m(162 lb ft).

53. Connect the park brake cables to the park brake apply levers and brackets.
54. Connect the outer tie rod end studs to the rear suspension knuckles.
55. Install the outer tie rod end nuts.

Tighten

•	Tighten the outer tie rod end nuts to 20 N·m(15 lb ft) to seat the outer tie rod studs.

•	Turn the nuts additional 160 degrees.

•	Check the outer tie rod end nuts for a minimum torque of 45 N·m(33 lb ft).

56. Install the brake calipers to the caliper mounting brackets.

Tighten
Tighten the brake caliper guide pin bolts to 31 N·m(23 lb ft).

57. Connect the shock absorber solenoid electrical connectors, if equipped.
58. Connect the electronic suspension control (ESC) position sensor links, if equipped.
59. Connect the electrical connectors to both wheel speed sensors.
60. Remove J 33432-A Transverse Spring Compressor from the rear transverse spring.
61. Install the rear tire and wheel assemblies.
62. Refill the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual.
63. Lower the vehicle.

1. Raise and support the vehicle.
2. Remove the left rear tire and wheel assembly.
3. Install J 33432-A Transverse Spring Compressor to the rear transverse spring and compress the spring.
4. Disconnect the electrical connector from the left wheel speed sensor.
5. Disconnect the electronic suspension control (ESC) position sensor link, if equipped.
6. Disconnect the shock absorber solenoid electrical connector, if equipped.
7. Remove the outer tie rod end nut.
8. Disconnect the outer tie rod end stud from the rear suspension knuckle.
9. Disconnect the park brake cable from the park brake apply lever and bracket.
10. Remove the bolts securing the upper control arms to the frame.
11. Remove the spindle nut retaining the rear wheel axle shaft to the hub.
12. Rotate the suspension knuckle until the axle shaft clears the hub.
13. Release and remove the rear wheel axle shaft from the differential.
14. Remove the left muffler.
15. Drain the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual.
16. Remove the retaining bolts and the damper/tuned absorber from the differential (97-04 model years).
17. Loosen the nut retaining the transmission to the transmission LH mounting stud.
18. Install a second nut onto the stud.
19. Remove the stud from the differential cover.
20. Clean any dirt or debris from around the differential cover.
21. Remove the bolts retaining the differential cover.
22. Remove the differential cover from the differential.
23. Remove and discard the O-ring seal and the axle seal from the differential cover.
24. Clean the O-ring sealing surface on the differential cover and the differential housing.
25. Install new O-ring, P/N 89047953, to the differential cover.
26. Apply a continuous 3 mm (0.125 in) bead of sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the cover flange.
27. Apply sealant around the bolt holes. Keep sealant away from the O-ring.
28. Install the differential cover to the differential.
29. Install the differential cover retaining bolts.

Tighten
Tighten the bolts to 28 N·m(20 lb ft).

30. Clean the excess sealant from the left cover/housing splitline.
31. Using two nuts installed on the stud, install the transmission mounting stud to the differential cover.

Tighten
Tighten the stud to 42 N·m(31 lb ft).

32. Remove the second nut from the transmission mounting stud.
33. Tighten the nut retaining the transmission to the transmission LH mounting stud.

Tighten
Tighten the nut to 50 N·m(37 lb ft).

34. Install the damper/tuned absorber and bolts to the differential (97-04 model years).

Tighten
Tighten the bolts to 25 N·m(18 lb ft).

35. Install the new axle seal, PN 88996703, into the differential cover using J 46405.
36. Install the left muffler.
37. Install the rear wheel axle shaft to the differential.
38. Install the spindle nut retaining the rear wheel axle shaft to the hub.

Tighten
Tighten the spindle nuts to 160 N·m(118 lb ft).

39. Install the bolts securing the upper control arms to the frame.

Tighten
Tighten the upper control arm bolts to 110 N·m(81 lb ft).

40. Connect the park brake cable to the park brake apply lever and bracket.
41. Connect the outer tie rod end stud to the rear suspension knuckle.
42. Install the outer tie rod end nut.

Tighten

•	Tighten the outer tie rod end nut to 20 N·m(15 lb ft) to seat the outer tie rod stud.

•	Turn the nut additional 160 degrees.

•	Check the outer tie rod end nut for a minimum torque of 45 N·m(33 lb ft).

43. Connect the shock absorber solenoid electrical connector, if equipped.
44. Connect the electronic suspension control (ESC) position sensor link, if equipped.
45. Connect the electrical connector to the left wheel speed sensor.
46. Remove J 33432-A Transverse Spring Compressor from the rear transverse spring.
47. Install the left rear tire and wheel assembly.
48. Refill the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual.
49. Lower the vehicle.

For vehicles repaired under warranty, use: