Rear Drive Axle

Document ID: 1801623 Page 1 of 1
2009 Saturn VUE - AWD | VUE, VUE Hybrid (VIN Z), Captiva Sport Service Manual | Driveline/Axle | Rear Drive Axle |
Specifications | Document ID: 1801623
Fastener Tightening Specifications

Fastener Tightening Specifications
Specification
Application Metric English
Clutch Drum Cover Bolts 29 N·m 21 lb ft
Differential Clutch Control Module Screws 15 N·m 11 lb ft
Differential Drain Plug 39 N·m 29 lb ft
Differential Fill Plug 39 N·m 29 lb ft
Differential Front Mounting Nuts 122 N·m 90 lb ft
Differential Rear Housing Support Bushing Bolts 188 N·m 139 lb ft
Differential Side Cover Bolts 29 N·m 21 lb ft
Left Rear Differential Mounting Bolts 29 N·m 21 lb ft
© 2010 General Motors Corporation. All rights reserved.
http://localhost:9001/si/showDoc.do?docSyskey=1801623&pubCellSyskey=55636&pub... 11/15/2010
Rear Axle Specifications

Specification
Application Metric English
Gear Ratio 3.6L 2.53 2.53
Rear Differential Fill Quantity 500 ml 16.9oz
Adhesives, Fluids, Lubricants, and Sealers

Application Type of Material GM Part Number
Synthetic Gear Oil 75W- 89021677
GM Differential Lubricant
90 (Canadian P/N 89021678)
Propeller Shaft Mounting 88861429
Threadlocker
Bolts (Canadian P/N 88861430)
Repair Instructions | Document ID: 2168581
Rear Differential Clutch Control Module Replacement
Callout Component Name
Preliminary Procedures
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the exhaust system. Refer to Exhaust Muffler Replacement.
3. Remove the rear differential assembly. Refer to Differential Replacement.
Clutch Drum Control Module Screw (Qty: 2)
Caution: Refer to Fastener Caution in the Preface section.

1
Tighten
15 N·m (133 lb in)
2 Clutch Drum Control Module Connector
Clutch Drum Control Module
3 Procedure
Program the control module. Refer to Control Module References.
Rear Axle Lubricant Level Inspection
Preliminary Procedure
Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
Rear Differential Fill Plug
Tip
1 • The fluid level should be level with the bottom of the threads of the fill hole.
• If the fluid level is low, refer to Rear Axle Lubricant Replacement for the
proper fill instructions and type of fluid.
Tighten
39 N·m (29 lb ft)
Rear Axle Lubricant Replacement
Plug Differential Drain Plug
Caution: Refer to Component Fastener Tightening Caution in the Preface section.

1
Tighten
39 N·m (29 lb ft)
Differential Fill Plug
Tip
Fill the differential with GM P/N 89021677 (Canadian P/N 89021678) to the bottom
2
of the fill hole.
Tighten
39 N·m (29 lb ft)
Rear Wheel Drive Module Clutch Housing Replacement
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the propeller shaft from the differential clutch drum assembly. Refer to
Propeller Shaft Replacement.
1 Electrical Clutch Control Connector
2 Retaining Clip (Qty: 2)
Differential Clutch Drum Bolt (Qty: 4)
Tip
3
Relocate the rear portion of the propeller shaft to the side and support it with
mechanics wire or equivalent.
Tighten
29 N·m (21 lb ft)
Differential Clutch©Drum
2010 General Motors Corporation. All rights reserved.
Procedure
Rear differential clutch control module recalibration, refer to Control Module
4 References.
Tip
The pinion flange, dust cover and pinion nut are serviced with the differential clutch
drum assembly.
Differential Clutch Drum Gasket
5
Tip
Apply a small amount of grease to the gasket to hold it in place.
Differential Carrier Assembly Mount Replacement
Left Rear Differential Mount Nut
1 Tip
Support the rear differential with a jack stand.
Tighten
122 N·m (90 lb ft)
Left Rear Differential Mount Bolt (Qty: 2)
2
Tighten
29 N·m (21 lb ft)
Left Rear Differential Mount Bolt (Qty: 2)

3
Tighten © 2010 General Motors Corporation. All rights reserved.
29 N·m (21 lb ft)

4 Left Rear Differential Mount
Rear Axle Vent Replacement
Remove the rear differential assembly from the vehicle. Refer to Differential Replacement.
Rear Differential Vent
Procedure
1. Remove any dirt or debris from the vent area.
2. Using an appropriate pair of pliers, remove the vent from the rear differential
1 housing.
Tip
• The rear differential does not have to be removed from the jack stand to
perform this procedure.
• When installing the vent, use a deep well socket that fits on the flange of the
vent and gently tap the vent into place.
Differential Carrier Cover and Seal Replacement - Left

Side
Remove the rear differential assembly. Refer to Differential Replacement.
Differential Side Cover Bolt (Qty: 8)
Tip
1 • Finger tighten the bolts before torquing to specification.
• Tighten the bolts in a criss cross pattern.
Tighten
29 N·m (21 lb ft).
Differential Side Cover
2 Tip
Inspect the differential side cover for any damage. If the side cover is damaged,
replace the differential assembly. The side cover is not serviced separately.
Differential Side Cover Seal
Tip
3 • Before installing the side cover seal, ensure that the groove for the side cover
seal is free of dirt and debris. This will ensure that the seal seat properly in
the differential housing.
• Apply a small amount of clean oil to the side cover seal.
Rear Axle Shaft Seal Replacement - Left Side

Special Tools
• J 8092 Driver Handle

• J 33832 Rear Bearing Installer
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the rear differential. Refer to Rear Axle Lubricant Replacement .
3. Remove the muffler assembly. Refer to Muffler Replacement .
4. Remove the left rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
5. Using the appropriate tool, remove the axle shaft seal (1).
Installation Procedure
1. Using the J 8092 and the J 33832 , install the axle shaft seal (1).
2. Install the left rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
3. Install the muffler assembly. Refer to Muffler Replacement .
4. Fill the rear differential with fluid. Refer to Rear Axle Lubricant Replacement .
5. Remove the support and lower the vehicle.
Rear Axle Shaft Seal Replacement - Right Side

Special Tools
• J 8092 Driver Handle

• J 33832 Rear Bearing Installer
Removal Procedure
2. Drain the rear differential. Refer to Rear Axle Lubricant Replacement .
3. Remove the muffler assembly. Refer to Muffler Replacement .
4. Remove the right rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
5. Using the appropriate tool, remove the axle shaft seal (1).
1. Using the J 8092 and the J 33832 , install the axle shaft seal (1).
2. Install the right rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
3. Install the muffler assembly. Refer to Muffler Replacement .
4. Fill the rear differential with fluid. Refer to Rear Axle Lubricant Replacement .
5. Remove the support and lower the vehicle.
Drive Pinion Flange/Yoke and/or Oil Seal Replacement
2. Remove the differential clutch drum assembly. Refer to Rear Wheel Drive Module
Clutch Housing Replacement .
Differential Pinion Seal
Procedure
1. Install a sheet metal screw into the seal.
2. Attach a pair of pliers or a slider hammer to the screw and remove the seal.
3. Using the slide hammer or pliers, remove the seal.
4. Using the J 44636-1, install the pinion seal.
1 5. Inspect the fluid level. Refer to Rear Axle Lubricant Level Inspection .
Tip
The pinion flange, the nut and the dust cover are NOT SERVICED separately. These
items are serviced with the differential clutch drum assembly.
Special Tools
J 44636-1 Front Output Shaft Seal Installer
Differential Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Drain the rear differential, if needed. Refer to Rear Axle Lubricant Replacement.
3. Remove the exhaust system. Refer to Exhaust Muffler Replacement.
4. Remove the rear wheel drive shafts. Refer to Rear Wheel Drive Shaft Replacement.
5. Remove the propeller shaft from the vehicle. Refer to Propeller Shaft Replacement.
6. Support the rear differential with a transmission jack stand.
7. Remove the rear differential support bushing bolts.
8. Remove the front mounting nuts for the rear differential (3).
9. Lower the rear differential to gain access rear differential clutch control module.
10. Remove the small electrical connector from the control module (1).
11. Remove the large electrical connector from the control module (2).
12. Remove the rear differential assembly from the vehicle.
Note: When positioning the rear differential assembly in the rear cradle, leave enough room
to access the clutch control module.
1. Position the rear differential assembly in the rear cradle.
2. Install the small electrical connector (1).

3. Install the large electrical connector (2).
Note: When installing the front mounting bolts tighten by hand.
4. Install the front mounting nuts (3).
5. Install the rear differential support bushing bolts.

6. Raise the rear differential assembly into place.
7. Tighten the front mounting nuts. Tighten the nuts to 122 N·m (90 lb ft).
8. Tighten the rear differential support bushing bolts. Tighten the nuts to 188 N·m (139 lb ft).
9. Remove the transmission jack stand.
10. Install the propeller shaft. Refer to Propeller Shaft Replacement.
11. Install the rear wheel drive shafts. Refer to Rear Wheel Drive Shaft Replacement.
12. Install the exhaust system. Refer to Exhaust Muffler Replacement.
13. Fill the rear differential assembly with fluid, if drained. Refer to Rear Axle Lubricant
Replacement.
14. Lower the vehicle.
Differential Housing Support Bushing Replacement

(Front)
Remove the Rear Differential Module. Refer to Differential Housing Support Bushing
Replacement .
Rear Differential Mount Bushing
1
Tip
Use the appropriate tool to remove the bushing.
Differential Housing Support Bushing Replacement

(Rear)
Tools Required
J-45725 Cradle Bushing Replacer
Removal Procedure
2. Remove the rear differential assembly. Refer to Differential Replacement .
3. Mark a reference point on the frame and old bushing at the 12 and 6 o'clock position to use
to alignment the new bushing.
4. Position the J-45725-1A (1) on the bushing (2).

5. Position the J-45725-2A (1) on the frame.
Important: Apply a small amount of grease on the threaded rod to lubricate the nuts when
turning the nuts.
6. Install the threaded rod, bearing and washers.
7. Adjust the nuts so that they are touching the J-45725-1A (2) and the J-45725-2A (1).
8. Install the proper size wrenches on the nuts.
Important: In the following service procedure, use only HAND TOOLS when using the J-
45725.
9. While holding the front wrench (1) rotate the rear wrench (2) to remove the bushing.
10. Remove the special tools.
11. Remove the bushing from the frame.
Important: Failure to perform the following service procedure prior to the installation of the
new bushing, could cause premature failure of the bushing.
1. Before the installation of the new bushing, use a straight edge draw a line on the new
bushing at the 12 and 6 o'clock positions. Ensure that the grooves (1) are at the
12 and 6 o'clock positions.
2. Position the new bushing so that the reference marks on the frame and the bushing are in
alignment. This will ensure that the new bushing will be within the + or - 5° specification
required for the proper alignment of the bushing.
Important: The following procedure is to temporarily hold the new bushing in place so that
the special tools can be installed for the proper installation. This is NOT to be used to install
the bushing.
3. Using a block of wood and a hammer, slightly tap the bushing into the frame.
4. Assemble the threaded rod, bearings and washers as indicated in step 7 in the removal
procedure.
5. Position the J-45725-4 (2) on the inside of the frame.

6. Position J-45725-1A (1) on the outside of the frame.
7. Adjust the nuts so that they are touching the J-45725-2 (1) and the J-45725-2A (2).
8. While holding the front wrench (2) rotate the rear wrench (1) to install the bushing.
9. Remove the special tools.
10. Install the rear differential assembly. Refer to Differential Replacement .
11. Lower the vehicle.

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Document ID: 1801623 Page 1 of 1

Fastener Tightening Specifications

© 2010 General Motors Corporation. All rights reserved.

Rear Axle Specifications

© 2010 General Motors Corporation. All rights reserved.

Adhesives, Fluids, Lubricants, and Sealers

© 2010 General Motors Corporation. All rights reserved.

Rear Differential Clutch Control Module Replacement

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

Rear Axle Lubricant Level Inspection

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

Rear Axle Lubricant Replacement

Callout Component Name

Caution: Refer to Component Fastener Tightening Caution in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

Rear Wheel Drive Module Clutch Housing Replacement

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

Differential Carrier Assembly Mount Replacement

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

Left Rear Differential Mount Bolt (Qty: 2)

29 N·m (21 lb ft)

Rear Axle Vent Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

Differential Carrier Cover and Seal Replacement - Left

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

• Apply a small amount of clean oil to the side cover seal.

Rear Axle Shaft Seal Replacement - Left Side

• J 8092 Driver Handle

© 2010 General Motors Corporation. All rights reserved.

Rear Axle Shaft Seal Replacement - Right Side

• J 8092 Driver Handle

© 2010 General Motors Corporation. All rights reserved.

Drive Pinion Flange/Yoke and/or Oil Seal Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

7. Remove the rear differential support bushing bolts.

© 2010 General Motors Corporation. All rights reserved.

12. Remove the rear differential assembly from the vehicle.

1. Position the rear differential assembly in the rear cradle.

2. Install the small electrical connector (1).

Note: When installing the front mounting bolts tighten by hand.

4. Install the front mounting nuts (3).

5. Install the rear differential support bushing bolts.

Caution: Refer to Fastener Caution in the Preface section.

Differential Housing Support Bushing Replacement

Callout Component Name

© 2010 General Motors Corporation. All rights reserved.

Differential Housing Support Bushing Replacement

© 2010 General Motors Corporation. All rights reserved.

4. Position the J-45725-1A (1) on the bushing (2).

6. Install the threaded rod, bearing and washers.