ALL WHEEL DRIVE REAR HYPOID AXLE DIAGNOSIS. Pontiac 6000 1988

For 1990-2009 cars

# ALL WHEEL DRIVE REAR HYPOID AXLE DIAGNOSIS

SAGINAW ALL-WHEEL-DRIVE (F73) REAR HYPOID AXLE (3.42R, ZZA) ASM. DIAGNOSIS, LIMITED REPAIR AND EXCHANGE PROCEDURE

#### Models Affected 1988 PONTIAC 6000 STE (Y88) WITH --------------- ALL-WHEEL-DRIVE (F73) OPTION

To gain product feedback on the above axle assembly, and to minimize downtime an axle exchange program is now in effect and will continue until further notice. (Probably SOP 1989)

The exchange program will be administered by Saginaw Division and all requests for exchange units will be handled through the Pontiac Technical Assistance Service (TAS).

The following information from Pontiac and Saginaw Division thoroughly explains all requirements regarding diagnosis, serviceable and non- serviceable items, serviceable part numbers, warranty claims processing procedures and shipping instructions.

If your dealership receives a complaint on a Pontiac 6000 STE All-Wheel-Drive axle assembly, follow the procedure listed below.

#### NOTE:

- Numbers in brackets refer to item numbers on disassembled view, figure 1.

A. Preliminary

o Refer to DIAGNOSIS CHART, section 3.

o Ensure proper oil level. Use GM part number 1052271, LUBRICANT, REAR AXLE.

o Ensure that all differential mounting and prop shaft flange connecting bolts are tight.

B. On-car service (without exchange)

o Oil leaks at fill plug and/or washer. Fill plug torque is 26-40nm.

C. Out-of-car Repairs (WITH Exchange) :

o All other repairs to the differential unit.

D. Exchange Procedure ------------------

1. Call your Pontiac Technical Assistance Service (TAS) for handling the exchange request. (1-800-742-4636)

2. Provide them the necessary information. Fill out the Axle Reporting Form (attached) prior to calling.

3. TAS will arrange to ship an exchange unit to your dealership.

4. TAS will provide dealership with an authorized "Case Request Number". This number must be written on the unit (differential carrier assembly ) with a permanent marker as well as on the shipping container used to return the unit to Saginaw Division - Detroit.

5. Once the exchange unit is received, the concerned unit is to be returned to: Saginaw Division - Detroit Operations 1840 Holbrook Avenue Detroit, MI 48212 Attn: Quality Assurance, Plant 58

6. The exchange unit will have an envelope attached to it. This envelope will contain: o Return Shipping Label o All-Wheel-Drive Reporting Form o Return Shipping Carrier information

7. The concerned unit must be returned within 5-7 days after receipt of the exchange unit.

E. Preparation for Shipping ------------------------

1. Drain the oil from the axle assembly and replace the drain plug.

2. Fold the Reporting Form, insert it into the resealable bag provided with the exchange unit and attach the bag securely to the differential carrier assembly of the concerned unit.

3. Write the TAS "Case Request Number" on the differential carrier assembly and shipping container.

4. Repack the concerned unit into the original shipping container per the instructions provided.

5. Place the shipping label on the original shipping container.

6. The unit should be shipped C.O.D.

F. Warranty Claims Processing Procedure ------------------------------------

Upon completion of the repair, a warranty claim is to be submitted to Pontiac for only the labor for the R and R and differential fluid. A special labor operation is provided for this situation and is the only labor operation to be used in the event an exchange unit is used. Use appropriate trouble code.

Labor Operation: T3240

Labor Time: 3.8 Hours

Material Allowance (For Differential Fluid) 2 Quarts

DIAGNOSIS OF REAR AXLE ASM

#### ROAD TEST

o Check tires for irregular wear o Check tire pressure o Check axle lubricant level o Drive to warm up the rear axle o Test a various speeds in drive, float, coast and while cornering.

#### TIRE NOISES

o Change the tire pressure to minimize noises. o Drive over different road surfaces. o Smooth blacktop minimizes tire noise. o Cross switch the tires if necessary. o Snow tire treads and studs cause added noises.

#### ENGINE OR EXHAUST NOISES

o Drive slightly above the speed where the noise occurs, place transmission in neutral. o Let the engine speed drop to idle. o Stop the vehicle. o Run the engine at various engine speeds.

#### WHEEL BEARING NOISE

o Drive the vehicle at low speed on a smooth road. o Turn the vehicle to develop left and right motions, traffic permitting. o Noise should change due to cornering loads. o Jack up the wheels to verify roughness at the wheels.

#### DIFFERENTIAL BEARING NOISE

o Drive the vehicle at low speed on a smooth road. o Constant low pitch bearing noise may be heard. o Noise should not change in reversing turns. o The noise pattern should vary with the wheel speed.

#### PINION BEARING NOISE

o Rough running or a whine noise should increase with wheel speed. o Noise pitch should be higher than differential noise. o Perform the test on a smooth road to minimize tire noises. o Perform the test at various speeds in drive, float and coast. o Rear pinion bearing noise may be louder on acceleration. o Front pinion bearing noise may be louder on deceleration. o Gear noise tend to peak in a narrow speed range.

1988 PONTIAC 6000 STE ALL-WHEEL-DRIVE REAR DIFFERENTIAL EXCHANGE PROGRAM REPORTING FORM

DEALER CODE _________________ NOISE/VIBRATION BEARING NOISE

DEALER NAME/ADDRESS __________ PINION ______________________________ DIFFERENTIAL _________________________

______________________________

______________________________ GEAR NOISE 10 - 25 MPH _________________________ PHONE _______________________ 25 - 45 MPH _________________________ 45 - 65 MPH _________________________ VIN _______________________

MILEAGE ______________________ DRIVE ________ FLOAT ________ DEALER RO NO. ________________ COAST ________

RO DATE ______________________ LEAK AT EXTENSION TO DIFFERENTIAL CARRIER ______________________________

REQUEST NO. __________________

SERVICE MGR. _________________ LEAK AT DIFFERENTIAL CARRIER HALVES _____________________________________ SERVICE MGR.__________________ CASE POROSITY _______________________ TAS NO. ______________________ BROKEN OR CRACKED CASE ______________

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.