C-5 TECH ?? diff. leak
 

2 questions C-5 TECH
- Do you have any opinion or theories as to why the left side seal /O ring leaks most times and not the right side. I believe both sides use the same parts.
-TSB #03-04-20-006 Diff leak mentions SI Document ID #675189 in connection with drain and refill of the differential. What information does this document provide ?

TIA I am about to go to the dealer for this repair and would like to be informed as much as possible.

Jerry

No theory, but mine goes in for that repair today as well.

All my C5's to date have not had a leak. There is a survey in the Z06 forum and most have not had a problem. This is with many miles and includes several track runs. My theory is that it must be a QC issue at Getrag. Pehaps the part tolerances are out of spec causing the seals to leak. There is another theory about case stress due to the single mount design (corrected on C6) but not all cars have the issue.

http://forums.corvetteforum.com/showthread.php?t=850993

Had mine fixed a week ago, so far so good. :flag:

Because it is so common for the left side to leak and somewhat rare for the right side to leak,I believe that the cover or the mating surface on the rear differential are not machined correctly for a proper fit.They all seem to leak at about 8 o'clock on the cover and the oil always leaves the same telltale trail.
There is a TSB that has the updated axle and o-ring seals that were released to address the problem.It also states to use anerobic sealer on the cover which is excellent for alluminum machined surfaces.Anerobic sealer creates a seal when not in the presence of oxygen and should be left to cure for 24 hours before fluid is added.The only problem is that these new seals went into production on the 2003-04 and the left covers continue to leak past the o-ring :yesnod: Late 04's now have the sealer applied to the cover and I have seen them leak also.If GM suggests to use sealer in addition to the new design o-ring,they must not have been too confident that the new design o-ring (a hair thicker)would cure the problem :rolleyes:Why dont they simply design a side cover gasket? :confused:
Out of the 65-75 rear end leaks that I have addressed,a few more than what I would like have come back with reoccuring leaks after using the new seals and anerobic sealer.Recently I started using a small bead of silicone sealer on the cover instead of the anerobic sealer.My thinking is that the anerobic sealer can not fill a void in the mating surfaces because it remains pliable when in the presence of oxygen.

Fluid Leak at Rear Axle (Replace Left Differential SIde Cover O-Ring and Left Axle Shaft Seal, Add Sealant to Side Cover Flange) #03-04-20-006 - (Nov 18, 2003)
Fluid Leak at Rear Axle (Replace Left Differential Side Cover O-Ring and Left Axle Shaft Seal, Add Sealant to Side Cover Flange)
2004 Cadillac XLR

1997-2004 Chevrolet Corvette

Condition
Some customers may comment on fluid leaking from the rear axle.

Correction
Verify that the fluid leak is rear axle fluid, not transmission fluid. Replace the left differential side cover O-ring and left axle shaft seal. Engineering has recommended that sealant be applied to the side cover prior to installation. Use the appropriate service procedure and part numbers listed below.

Service Procedure (Cadillac XLR)
Raise and support the vehicle.
Remove the rear tire and wheel assemblies.
Install J 33432-A Transverse Spring Compressor to the rear transverse spring and compress the spring.
Disconnect the electrical connectors from both wheel speed sensors.
Disconnect the electronic suspension control (ESC) position sensor links, if equipped.
Disconnect the shock absorber solenoid electrical connectors, if equipped.
Remove the brake calipers from the caliper mounting brackets and support aside.
Remove the outer tie rod end nuts.
Disconnect the outer tie rod end studs from the rear suspension knuckles.
Disconnect the park brake cables from the park brake apply levers and brackets.
Remove the shock absorber lower mounting bolts from the lower control arms.
Remove the bolts securing the upper control arms to the frame.
Remove the spindle nuts retaining the rear wheel axle shafts to the hubs.
Rotate the suspension knuckles until the axle shafts clear the hubs.
Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
Release brake pipes from underbody clips.
Remove the transaxle mount to rear crossmember nuts.
Position an adjustable jack stand under the transmission and support the transmission.
Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
Remove the rear suspension crossmember mounting nuts.
Slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
Release and remove the rear wheel axle shafts from the differential.
Remove the intermediate exhaust pipe.
Remove the left muffler.
Drain the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual (SI Document ID #675189).
Remove the left differential mount.
Clean any dirt or debris from around the differential cover.
Remove the bolts retaining the differential cover.
Remove the differential cover from the differential.
Remove and discard the O-ring seal and the axle seal from the differential cover.
Clean the O-ring sealing surface on the differential cover and the differential housing.
Install new O-ring, P/N 89047953, to the differential cover.
Apply a continuous 3 mm (0.125 in) bead of sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the cover flange.
Apply sealant around the bolt holes. Keep sealant away from the O-ring.
Install the differential cover to the differential.
Install the differential cover retaining bolts. Tighten
Tighten the bolts to 28 N·m(20 lb ft).

Clean the excess sealant from the left cover/housing splitline.
Install the new axle seal, P/N 88996703, into the differential cover using J 46405.
Install the left differential mount.
Install the left muffler.
Install the intermediate exhaust pipe.
Install the rear wheel axle shafts to the differential.
Install the rear suspension crossmember.
Align the crossmember dowel pins to the holes in the frame rails.
Align the transaxle mount studs to the crossmember.
Install the rear suspension crossmember mounting nuts. Tighten
Tighten the crossmember mounting nuts to 110 N·m(81 lb ft).

Remove the transmission jack from the crossmember.
Remove the adjustable jack stand from under the transmission.
Install the transaxle mount to rear crossmember nuts. Tighten
Tighten the transaxle mount nuts to 50 N·m(37 lb ft).

Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
Install the brake pipes to the underbody clips.
Install the spindle nuts retaining the rear wheel axle shafts to the hubs. Tighten
Tighten the spindle nuts to 160 N·m(118 lb ft).

Install the bolts securing the upper control arms to the frame. Tighten
Tighten the upper control arm bolts to 110 N·m(81 lb ft).

Install the shock absorber lower mounting bolts to the lower control arms. Tighten
Tighten the shock absorber lower mounting bolts to 220 N·m(162 lb ft).

Connect the park brake cables to the park brake apply levers and brackets.
Connect the outer tie rod end studs to the rear suspension knuckles.
Install the outer tie rod end nuts. Tighten
Tighten the outer tie rod end nuts to 20 N·m(15 lb ft) to seat the outer tie rod studs.
Turn the nuts additional 160 degrees.
Check the outer tie rod end nuts for a minimum torque of 45 N·m(33 lb ft).
Install the brake calipers to the caliper mounting brackets. Tighten
Tighten the brake caliper guide pin bolts to 31 N·m(23 lb ft).

Connect the shock absorber solenoid electrical connectors, if equipped.
Connect the electronic suspension control (ESC) position sensor links, if equipped.
Connect the electrical connectors to both wheel speed sensors.
Remove J 33432-A Transverse Spring Compressor from the rear transverse spring.
Install the rear tire and wheel assemblies.
Refill the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual (SI Document ID #675189).
Lower the vehicle.
Service Procedure (Corvette)
Raise and support the vehicle.
Remove the left rear tire and wheel assembly.
Install J 33432-A Transverse Spring Compressor to the rear transverse spring and compress the spring.
Disconnect the electrical connector from the left wheel speed sensor.
Disconnect the electronic suspension control (ESC) position sensor link, if equipped.
Disconnect the shock absorber solenoid electrical connector, if equipped.
Remove the outer tie rod end nut.
Disconnect the outer tie rod end stud from the rear suspension knuckle.
Disconnect the park brake cable from the park brake apply lever and bracket.
Remove the bolts securing the upper control arms to the frame.
Remove the spindle nut retaining the rear wheel axle shaft to the hub.
Rotate the suspension knuckle until the axle shaft clears the hub.
Release and remove the rear wheel axle shaft from the differential.
Remove the left muffler.
Drain the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual (SI Document ID #675189).
Remove the retaining bolts and the damper/tuned absorber from the differential.
Loosen the nut retaining the transmission to the transmission LH mounting stud.
Install a second nut onto the stud.
Remove the stud from the differential cover.
Clean any dirt or debris from around the differential cover.
Remove the bolts retaining the differential cover.
Remove the differential cover from the differential.
Remove and discard the O-ring seal and the axle seal from the differential cover.
Clean the O-ring sealing surface on the differential cover and the differential housing.
Install new O-ring, P/N 89047953, to the differential cover.
Apply a continuous 3 mm (0.125 in) bead of sealant, P/N 1052942 (Canadian P/N 10953466), or equivalent, to the cover flange.
Apply sealant around the bolt holes. Keep sealant away from the O-ring.
Install the differential cover to the differential.
Install the differential cover retaining bolts. Tighten
Tighten the bolts to 28 N·m(20 lb ft).

Clean the excess sealant from the left cover/housing splitline.
Using two nuts installed on the stud, install the transmission mounting stud to the differential cover. Tighten
Tighten the stud to 42 N·m(31 lb ft).

Remove the second nut from the transmission mounting stud.
Tighten the nut retaining the transmission to the transmission LH mounting stud. Tighten
Tighten the nut to 50 N·m(37 lb ft).

Install the damper/tuned absorber and bolts to the differential. Tighten
Tighten the bolts to 25 N·m(18 lb ft).

Install the new axle seal, PN 88996703, into the differential cover using J 46405.
Install the left muffler.
Install the rear wheel axle shaft to the differential.
Install the spindle nut retaining the rear wheel axle shaft to the hub. Tighten
Tighten the spindle nuts to 160 N·m(118 lb ft).

Install the bolts securing the upper control arms to the frame. Tighten
Tighten the upper control arm bolts to 110 N·m(81 lb ft).

Connect the park brake cable to the park brake apply lever and bracket.
Connect the outer tie rod end stud to the rear suspension knuckle.
Install the outer tie rod end nut. Tighten
Tighten the outer tie rod end nut to 20 N·m(15 lb ft) to seat the outer tie rod stud.
Turn the nut additional 160 degrees.
Check the outer tie rod end nut for a minimum torque of 45 N·m(33 lb ft).
Connect the shock absorber solenoid electrical connector, if equipped.
Connect the electronic suspension control (ESC) position sensor link, if equipped.
Connect the electrical connector to the left wheel speed sensor.
Remove J 33432-A Transverse Spring Compressor from the rear transverse spring.
Install the left rear tire and wheel assembly.
Refill the rear differential fluid. Refer to the Lubricant Change procedure in the Rear Axle sub-section of the Service Manual (SI Document ID #675189).
Lower the vehicle.
Parts Information
Part Number
Description
Qty

88996703
Seal, Output Shaft Oil
1

89047953
O-Ring, Differential Side Cover
1

1052942 (Canada 10953466)
Sealant
1


Parts are currently available from GMSPO.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

F9701* (XLR Only)
Rear Axle Seal Replace -- Side Cover and Axle Shaft
2.3 hrs

F9701* (Corvette Only)
Rear Axle Seal Replace -- Side Cover and Axle Shaft
1.6 hrs

C5TECH: Can you move the cover back say 1/8" and apply the silcone and torque bolts while in the car???

:bigears :lurk:

F9701* (Corvette Only)
Rear Axle Seal Replace -- Side Cover and Axle Shaft
1.6 hrs[/QUOTE]


Per your description, this is charged at 1.6 hours. I just took the car in this morning for the same issue, and the dealer estimated a total cost of $474 to fix. At $80 per hour, this seems quite high. What have others paid for this fix? :ack:

You are so lucky---all five of our C5s have had the leak, two of them several times.

Roy

Per your description, this is charged at 1.6 hours. I just took the car in this morning for the same issue, and the dealer estimated a total cost of $474 to fix. At $80 per hour, this seems quite high. What have others paid for this fix? :ack:[/QUOTE]

1.6 labor hours is what GM will reimburse the dealer for the repair under warranty.It is also what the tech will be paid to perform the repair x's his hourly rate under warranty.Warranty labor times dont even come close to reflecting the actual time to perform the repair.If you are paying out of pocket,Chilton time or book time for a specific repair will be alot more than warranty labor time :yesnod:

You would have to remove the axle shaft to back off the cover.Once you remove the axle you are 6 bolts from simply removing the cover.Wouldnt make sense ;)

Just had my 2001 coupe done- out of warranty. I brought some info from this forum to the dealer and they paid for half the repair. So far it is holding. My cost $150.00

What info did you take to the dealer? I am supposed to pick the car up today at noon. I would like to fight this and try to get GM to pay at least half!

C-5 Tech

Thanks for the info. My '03 Z06 w/ 7500 miles goes in on Monday for the repair.

-Rob

C5- TECH 2nd part of my ? what is SI Document ID #675189all about.

Jerry

Here's my theory:

There is one bolt for that side cover that goes forward and mates to the transmission. I believe if that bolt is over tightened, or even tightened to spec, it pulls the side cover forward slightly, probably not detectible by the human eye. But it might be enough to change the mating of the side place to the diff. I used the sealer when I did mine and just snugged the forward facing bolt. I've been leak free since, 5K miles later...

Some of you guys that have paid out of your pocket because you were out of warranty may want to take a look at this thread.

:cheers:

http://forums.corvetteforum.com/showthread.php?t=882517

Mine was done about two weeks ago, so far no problem.

Document ID# 675189


--------------------------------------------------------------------------------

Lubricant Change
Draining Procedure




Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Clean any dirt from around the differential drain plug.
Remove the drain plug and washer from the differential.
Drain the fluid.
Filling Procedure





Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



Important
Do not operate the vehicle at wide open throttle for a minimum of 480 km (300 miles) after refilling the differential with lubricant and friction modifier. Scoring of the ring and pinion gears may result, leading to differential noise.


Install the drain plug and washer to the differential. Tighten
Tighten the differential drain plug to 35 N·m (26 lb ft).





Clean any dirt from around the differential fill plug.
Remove the fill plug, lubricant tag, and washer from the differential.
Fill the differential with fluid:
Fill with synthetic axle lubricant GM P/N 1237826 (Canadian P/N 10953455).
Add approximately 118 ml (4.0 oz) limited-slip differential lubricant additive GM P/N 1052358 (Canadian P/N 992694).
Check the fluid level to ensure it is even with the bottom of the fill plug hole to no lower than 6 mm (0.25 in) below the opening.
Install the fill plug, lubricant tag, and washer to the differential. Tighten
Tighten the differential fill plug to 35 N·m (26 lb ft).

Lower the vehicle.