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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1875 (Rear Drive Axle) >> Repair Instructions >> Differential Clutch Drum Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Filter Assembly
    GM735400Courtesy of GENERAL MOTORS CORP.
  1. Install a new filter assembly.
  2. Install the locating pins.
    3. Fig 2: Aligning Clutch With Pump & Pump Bushing
    GM1356901Courtesy of GENERAL MOTORS CORP.
  3. Align the clutch with the pump and pump bushing. Place the J 46607  in the splines of the clutch. See Special Tools . 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. See Special Tools . Remove the tool by pulling straight out.
    4. Fig 3: Clutch Drum & Pinion Shaft
    GM1253119Courtesy of GENERAL MOTORS CORP.
    NOTE: 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. Fig 4: Clutch Drum Oil Seal
    GM1253122Courtesy of GENERAL MOTORS CORP.
  5. When properly engaged, the clutch drum will be fully seated against the clutch drum oil seal (1).
    6. Fig 5: RDM Housing Sealing Surface
    GM792851Courtesy of GENERAL MOTORS CORP.
  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).

    7. NOTE: 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.
    Fig 6: Clutch Housing Cover & RDM
    GM1253125Courtesy of GENERAL MOTORS CORP.
  7. Install the clutch housing cover (1) to the RDM.
    8. NOTE: Refer to Fastener Notice .
  8. Hand install the clutch housing cover bolts (2).

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

    9. Fig 7: Inspecting Dust Deflector For Cracks
    GM693550Courtesy of GENERAL MOTORS CORP.
  9. Install the dust deflector (2) to the input flange (1) if removed.
    10. Fig 8: Removing/Installing Input Flange On The Clutch Shaft
    GM693549Courtesy of GENERAL MOTORS CORP.
  10. Install the input flange (2) to the clutch shaft.
  11. Hand install a new input flange nut (1) to the clutch shaft.
    12. Fig 9: Installing J44873 On The Pinion Flange
    GM1265096Courtesy of GENERAL MOTORS CORP.
  12. Install the J 44873  (1) to the pinion flange (2) using the J 44873-2 shoulder bolts. See Special Tools .
  13. Using a breaker bar to hold the J 44873  stationary, tighten the pinion nut. See Special Tools .

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

    14. Fig 10: Removing/Installing RDM Drain Plug
    GM693541Courtesy of GENERAL MOTORS CORP.
  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. Fig 11: Removing/Installing Fill Plug
    GM792776Courtesy of GENERAL MOTORS CORP.
  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. Fig 12: Removing/Installing Propeller Shaft Flange Mounting Bolts
    GM928922Courtesy of GENERAL MOTORS CORP.
  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. Fig 13: View Of Propeller Shaft
    GM935370Courtesy of GENERAL MOTORS CORP.
  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.
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