Drivetrain - Moan/Growl/Vibration on Low Speed Turns
Bulletin No.: 03-04-20-003BDate: December 09, 2004
TECHNICAL
Subject:
Moan/Growl Noise/Vibration from Rear of Vehicle when Turning at Low Speeds (Replace Rear Drive Module Differential Clutch Drum)
Models:
2003-2004 Saturn VUE Vehicles with All Wheel Drive (AWD)
Attention:
Technician
Supercede:
This bulletin is being revised to update the part number information and add an important statement and sealing procedure. Please discard Corporate Bulletin Number 03-04-20-003A (Section 04 - Driveline/Axle).
Important:
This bulletin does NOT apply to 2004 Saturn VUE vehicles with 3.5L V-6 (L66) engines and AWD built between and including VIN breakpoint 4S800001-4S892254. For vehicles with 3.5L V-6 (L66) and AWD within this VIN range, refer to Customer Satisfaction Program 04090.
Condition:
Some customers may comment on a moan, growl noise, or vibration coming from the rear of the vehicle when turning at low speeds (such as parking lot maneuvers). Saturn VUE vehicles equipped with a VTi transmission (RPO M16) may also make clunking/rattle noises from the front transaxle area during the same driving conditions.
Cause:
Water contamination of the differential clutch plates in the rear drive module (RDM) may cause the clutch plates to chatter on turns.
Correction:
Replace the differential clutch drum in the RDM and replace RDM filter. On vehicles produced prior to VIN 3S849825, install a vent cap on the RDM vent hose to prevent water intrusion. Follow the "Differential Clutch Drum Assembly Replacement" procedure in the Driveline/Axle section of the 2004 Saturn VUE Service Manual, Vol. 1 to perform this repair with the RDM in the vehicle.
Diagnostic Procedure:
1. Test drive vehicle to confirm customer comment.
2. Remove propshaft and test drive vehicle under same conditions.
^ If noise is gone, replace RDM differential clutch drum and RDM filter using the "Differential Clutch Drum Assembly Replacement" procedure in the Driveline/Axle section of the 2004 Saturn VUE Service Manual, Vol. 1. This procedure also applies to 2003 model year vehicles. On vehicles produced prior to VIN 3S849825, install a vent cap, P/N 03820840, on the RDM vent hose to prevent water intrusion.
^ If noise remains, refer to the 2003 Saturn VUE Chassis Service Manual for diagnosis of rear suspension noises, or the 2003 Saturn VUE Transaxle Service Manual for diagnosis of transaxle noises. For 2004 vehicles, refer to the Suspension section of the 2004 Saturn VUE Service Manual, Vol. 1 for diagnosis of rear suspension noises, or the Transmission/Transaxle section of the 2004 Saturn VUE Service Manual, Vol. 2 for diagnosis of transaxle noises.
Sealing Procedure:
Note:
Do not use excessive amounts of sealant. Excess sealant could plug the vent passage, enter the oil pump, and/or the oil pump screen causing component failure.
Important:
Ensure sealing surface is clean and oil free.
1. Thoroughly clean the sealing surfaces with brake clean, or equivalent, and allow the surfaces to dry.
2. Use one of the RTV sealants from the chart in this bulletin. Apply a continuous bead of sealant 2.5 mm (0.098 in) in diameter to the sealing surface of the differential housing.
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Parts Requirements
Important:
Use the correct part for the application. The 2004 VUE with the 3.5L V-6 (L66/MJ8) has a unique differential clutch drum.
Important:
Allow Permatex(R) Right Stuff/Loctite(R) 5900 sealant to skin for 5 minutes before assembly.
Claim Information:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for F2240 (Plates or Drum, Limited Slip Differential - Replace).
Claiming Loctite(R) Threadlocker 592, Loctite(R) Threadlocker 262, and Sealant - Right Stuff
It will be necessary to sell these materials to the CSO as "material" using net item code "M" per the Parts Information chart in this bulletin. Claims received in the amount of $9.59 will be accepted. Claims exceeding the amount of $9.59 will be returned with Return Reason 143 - material/reimbursement > maximum allowed.
Disclaimer