Drivetrain - Rear Differential Fluid Leak
TECHNICALBulletin No.: 08-04-20-007
Date: October 13, 2008
Subject:
Rear Axle Fluid Leak (Tap Drain Plug Hole)
Models:
2009 HUMMER H2
Condition
Some customers may comment that the rear axle is leaking fluid. This condition may be noticed during new vehicle pre-delivery inspection (PDI) procedures. A visual inspection may reveal that the fluid is leaking from the rear axle drain plug.
Cause
The cause of this condition may be a drain plug hole that did not have the threads completely tapped when the axle was manufactured. The drain plug may be driven and torqued, but the incomplete thread does not allow the drain plug to fully seat and seal the drain hole.
Correction
This condition can be repaired by re-tapping the drain plug hole. It will be necessary to obtain a tap locally. Use an M20 X 1.5 Metric Tap, such as Snap-On(R) part number DR2015M, or equivalent. Use the following procedure:
1. Remove the drain plug and drain the lubricant from the axle. Capture the lubricant so it can be re-used.
2. Remove the rear axle cover pan so that chips may be removed after re-tapping the hole.
3. Using the M20 X 1.5 tap (1), hand start the tap several turns until resistance is felt.
4. Run the tap (1) into the carrier until resistance is no longer felt (should be no more than four turns).
5. Thoroughly clean the bottom of the inside of the axle housing to remove all chips from the tapping operation.
6. Install the drain plug.
Tighten
Tighten the plug to 33 Nm (24 lb ft).
7. Install the rear axle cover pan.
Tighten
Tighten the bolts to 39 Nm (29 lb ft).
8. Remove the fill plug and refill the axle with the lubricant previously removed. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening.
9. Install the fill plug.
Tighten
Tighten the plug to 33 Nm (24 lb ft).
Warranty Information
For vehicles repaired under warranty, use the table.
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