Tools Required

1. Raise and support the vehicle. Refer to Lifting and Jacking 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) using M10x1.50x30 bolts.
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.

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.

Important: The clutch drum may require some slight rotational movement to install completely. If the clutch is not fully seated, the clutch housing may break when tightening the bolts.

4. Install the clutch drum (1) to the pinion shaft .



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 21019581 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 in).

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 the Preface section.

8. Hand install the clutch housing cover bolts (2).

Tighten
Tighten the bolts to 26 N·m (19 lb ft).




9. Install the dust deflector (2) to the input flange (1) if removed.



10. Install the input flange (2) to the clutch shaft.
11. Hand install a new input flange nut (1) to the clutch shaft.



12. Install the J 44873 (1) to the pinion flange (2) using M10x1.50x30 bolts.
13. Using a breaker bar to hold the J 44873 stationary, tighten the pinion nut.

Tighten
Tighten the nut to 203 N·m (150 lb ft).




14. Thoroughly clean the drain plug threads and apply thread sealer Saturn P/N 21485278 to the plug threads.
15. Install the RDM drain plug.

Tighten
Tighten the plug to 30 N·m (22 lb ft).




16. Remove the RDM fill plug.
17. Thoroughly clean the fill plug threads and apply thread sealer Saturn P/N 21485278 to the plug threads.
18. Fill the RDM with lubricant. Refer to Rear Axle Lubricant Replacement .
19. Install the fill plug.

Tighten
Tighten the plug to 35 N·m (26 lb ft).




20. Thoroughly clean and apply threadlocker Saturn P/N 21005994 to the propeller shaft flange mounting bolt threads.
21. Align the reference marks on the propeller shaft flange and the RDM input flange.
22. Install the propeller shaft flange mounting bolts.

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




23. Install the propeller shaft underbody guard loop.
24. Install the propeller shaft underbody guard loop bolts.

Tighten
Tighten the bolts to 24 N·m (18 lb ft).

25. Lower the vehicle.