Differential PDF

2003 Pontiac Aztek
2003 DRIVE AXLES Differential - Aztek & Rendezvous
2003 DRIVE AXLES
Differential - Aztek & Rendezvous
DESCRIPTION & OPERATION

DIFFERENTIAL
The rear differential assembly consists of a torque tube assembly, three-piece differential housing, ring and
pinion, and a differential carrier assembly. See Fig. 2 . The aluminum torque tube housing contains an internal
drive shaft that is supported by roller bearings at each end. The internal drive shaft is retained to the front
propeller shaft assembly by bolts and splined to the differential pinion shaft. External to the tube are a vehicle
mounting bracket and a noise and vibration dampener.
The pinion shaft is positioned in an aluminum pinion housing and is supported by tapered roller bearings. See
Fig. 2 . A shim between the pinion and differential housings provides the proper backlash for the ring and
pinion. The ring gear is retained externally to the differential carrier assembly by bolts. Both the transfer case
hypoid gears and the rear differential assembly use unique type synthetic gear oil. The differential carrier
assembly consists of left and right side clutch pack drum, separate left and right axle sub shafts, left and right
gerotor pump components, left and right clutch packs, left and right pistons, and internal valves. See Fig. 2 .
The Versatrak(R) on-demand system operates as follows: The drive shaft assembly, mated to the output flange
of the transfer case, is constantly rotating and spins at a rate equal to an average of the two front wheels. Under
normal straight-ahead non-slip driving conditions, the external and internal gears of the differential gerotor
pumps are rotating at an equal rate of speed. Under those conditions, there is no speed differential between the
pump gears, no pump pressure created, no clutch pack activation, and no torque transfer. During a front-wheel
slip condition, the external gears of the gerotor pumps rotate at a faster rate of speed than the rear-wheel driven
internal gears. See Fig. 2 . The gerotor pumps pull oil from the sump through the clutch pump check valve
sending pressurized oil to each individual piston to activate the separate clutch packs. On-demand torque/drive
is provided to each of the rear wheels as required. A valve internal to each piston housing controls maximum
clutch pack pressure. A second valve within each housing is temperature compensating and controls fluid flow
based on ambient temperature. The system operates in both forward and rearward vehicle directions.
In the event a spare wheel of a smaller diameter is used on any of the four positions, the wheel rotational speed
difference is detected by the wheel speed sensors of the Anti-Lock Brake System (ABS) system. The
Powertrain Control Module (PCM) directs the clutch pump check valve to close and block oil flow to the
gerotor pumps. The clutch pump check valve also monitors the sump oil for an over-temperature condition. If
differential oil temperature exceeds 230°F (110°C), the valve will close and block oil flow to the gerotor pumps.
In both spare wheel usage and over-temperature conditions, a "closed" valve will alert the PCM to illuminate
the control panel AWD DISABLE light.
DIFFERENTIAL LOCK SYSTEM
The All Wheel Drive (AWD) system provides On-Demand all wheel drive, distributing variable torque/power
to the rear wheels via individual axle shaft assemblies. On-Demand drive is provided to each of the rear wheels
only when slippage is detected at the front wheels. As long as there is no slippage at the front wheels, there is
no front-to-rear speed differential and no need for rear wheel drive torque. In the event there is front-to-rear
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2003 Pontiac Aztek
wheel speed differential/slippage, a rotational speed difference between the gerotor pump components (rotor
and housing) occurs. In those instances, the rotor draws fluid from the sump and through the internal passages
of the differential carrier, sending pressurized fluid to a piston (actuating the specific rear wheel clutch pack). In
the event of a spare wheel (of smaller diameter) is used on any of the 4 positions, the wheel rotational speed
difference is detected by the wheel speed sensors of the ABS system. The powertrain module directs the
differential inlet valve to close and block oil flow to the gerotor pumps. The inlet valve also monitors the sump
oil for an "overtemperature" condition. If differential oil temperature exceeds 230°F (110°C), the valve will
close and block oil flow to the gerotor pumps. In both spare wheel usage and overtemperature conditions, an
activated inlet valve will illuminate the control panel AWD DISABLE indicator.
AWD DISABLE indicator
The AWD DISABLE indicator is located in the instrument panel cluster. This lamp is used to inform the driver
that the AWD system has been disabled and no torque will be applied to the rear wheels during a slip condition.
The AWD DISABLE indicator is controlled by the Powertrain Control Module (PCM) via a class 2 message.
Differential Clutch Pump Actuator Check Valve
The differential clutch pump actuator check valve controls the oil flow to the gerotor pumps. Without fluid
pressure, the pistons cannot apply the clutchpacks for rear wheel engagement. The actuator check valve will
open upon engine start-up and remain open unless commanded closed by the Powertrain Control Module
(PCM). The actuator check valve also monitors the sump oil for an overtemperature condition. If differential oil
temperature exceeds 230°F (110°C), the valve will close and block oil flow to the gerotor pumps
Powertrain Control Module
The Powertrain Control Module (PCM) monitors the data from the ABS controller and Rear Drive Module
(RDM) for proper operating conditions. If inappropriate conditions are present the PCM commands the
differential clutch pump actuator check valve closed, disabling the AWD system. The PCM also commands the
AWD DISABLE indicator on.
COMPONENT LOCATIONS
See Fig. 1 and Fig. 2 for views of differential assembly.
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Fig. 1: Exploded View Of Rear Axle Shaft & Differential

Courtesy of GENERAL MOTORS
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Fig. 2: Identifying Differential Components

Courtesy of GENERAL MOTORS CORP.
LUBRICATION
FLUID TYPE & CAPACITY
Use synthetic Gear Oil (12378514 for US; 88901045 for Canada). Fluid capacity is 2.1 qts. (1.9L).
LUBRICANT CHANGE
Raise and support the vehicle. Clean any dirt from around the differential drain plug. Position a drain pan under
drain plug. Remove the drain plug and gasket from the differential, and drain the oil. Install the drain plug and
gasket to the differential. Tighten the differential drain plug to specification. See TORQUE
SPECIFICATIONS . Clean any dirt from around the differential fill plug. Remove the fill plug from the
differential. Fill the differential with synthetic gear oil. See FLUID TYPE & CAPACITY . Inspect the gear oil
level to ensure it is even with the bottom of the fill plug hole to no lower than 0.25" (6 mm) below the opening.
Install the fill plug and gasket to the differential. Tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle. Drive the vehicle in tight left and right circles after filling the
differential in order to distribute the gear lubricant throughout the differential and engage the all-wheel-drive
system. Raise and support the vehicle. Remove the fill plug from the differential. Inspect the gear oil level to
ensure it is even with the bottom of the fill plug hole to no lower than 0.25" (6 mm) below the opening.
Reinstall the fill plug and gasket to the differential and tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle.
TROUBLE SHOOTING
DIAGNOSTIC STARTING POINT - REAR DIFFERENTIAL CARRIER
Begin the system diagnosis by reviewing the Fig. 1 , Fig. 2 , DIFFERENTIAL and DIFFERENTIAL LOCK
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SYSTEM under DESCRIPTION & OPERATION. Reviewing the description and operation information will
help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the
description and operation information will also help you determine if the condition described by the customer is
normal operation. See SYMPTOMS - REAR DIFFERENTIAL CARRIER in order to identify the correct
procedure for diagnosing the system and where the procedure is located.
DIAGNOSTIC STARTING POINT - REAR AXLE CONTROLS
Begin the system diagnosis with DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS . The
Diagnostic System Check will provide the following information:
 The Identification of the control module(s) which command the system.

 The ability of the control module(s) to communicate through the serial data circuit.
 The identification of any stored diagnostic trouble codes (DTCs) and their status.
The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and
where the procedure is located.
DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS
Circuit Description
The Diagnostic System Check is an organized approach to identify a condition created by the rear axle controls.
The Diagnostic System Check is the starting point for a rear axle controls complaint. The Diagnostic System
Check directs you to the next logical step for diagnosing a rear axle control concern. Perform this check only if
there is a driveability complaint or if you have been directed here from another service information section.
Follow the table to help reduce diagnostic time and help prevent unnecessary replacement of parts.
Diagnostic Aids
 Do not clear the DTC unless directed by a diagnostic procedure. Clearing the DTCs will erase all Freeze
Frame and Failure Records stored in PCM memory.
 Use a scan tool that is known to function correctly. If necessary, test the scan tool on another vehicle.
 Ensure the scan tool contains the most current file available.
 The scan tool will display a loss of communication error message under the following conditions:
A. The PCM power is interrupted.
B. The ignition switch is turned OFF.
C. The battery voltage level is very low.
D. A poor connection at the diagnostic link connector (DLC).
Testing
NOTE: Check for applicable service bulletins before proceeding with this test. Perform
this test only if there is a driveability complaint or if you have been directed to
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this table from another section in the service information. Do not turn the
ignition OFF when performing this diagnostic procedure. Do not clear the DTCs
unless instructed by this diagnostic procedure.
NOTE: This step determines if the scan tool is receiving power through the DLC
connector.
1. Install a scan tool. Turn ON the ignition, with the engine OFF. Does the scan tool turn ON? If so go to
next step. If not, go to SCAN TOOL DOES NOT POWER UP in appropriate BODY CONTROL
MODULES article.
NOTE: This step determines if the PCM is transmitting class 2 serial data to the
DLC and that the Class 2 data circuit is not open or shorted.
2. Attempt to establish communication with the PCM. Does the scan tool communicate with the PCM? If so
go to next step. If not, go to SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in
appropriate BODY CONTROL MODULES article.
NOTE: The presence of DTCs indicates that the powertrain control module has
detected a fault. Go to symptoms for other concerns.
3. Select the powertrain control module display DTCs function on the scan tool. Does the scan tool display
any DTCs? If so go to next step. If not go to SYMPTOMS - REAR AXLE CONTROLS .
NOTE: This step determines if a DTC is current or stored in history.
4. Does the scan tool display any DTCs which begin with a "U"? If so go to SCAN TOOL DOES NOT
COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article. If
not, go to appropriate SELF DIAGNOSTICS in FAULT ISOLATION under ENGINE
PERFORMANCE.
SYMPTOMS - REAR DIFFERENTIAL CARRIER
NOTE: For noise concerns, see TROUBLE SHOOTING in VIBRATION - DRIVETRAIN

under GENERAL INFORMATION article.
Visual/Physical Inspection
 Inspect for aftermarket devices, which could affect the operation of the vehicle.
 Inspect the easily accessible or visible system components for obvious damage or conditions, which could
cause the symptom.
 Check for the correct lubricant level and the proper viscosity.
 Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed,
road conditions, ambient temperature, and other specifics.
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 Compare the driving characteristics or sounds, if applicable, to a known good vehicle and make sure you
are not trying to correct a normal condition.
 Inspect for all-wheel drive activation and operation. See
 Factors that may contribute to an inoperative rear differential include:
A. Low gear oil levels.
B. Differential inoperative due to Anti-Lock Brake System (ABS) function.
C. Inoperative Powertrain Control Module (PCM) and/or wiring system.
D. A mini spare or different size tire installed.
E. A fluid over-temperature condition.
F. An inoperative or "stuck" clutch pump check valve.
G. A defective rear differential assembly.
H. An inoperative transfer case assembly.
SYMPTOMS - REAR AXLE CONTROLS
Visual/Physical Inspection
 Inspect for aftermarket devices which could affect the operation of the Rear Axle Control System.
 Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
 Inspect the rear axle for the proper fluid level.
Symptom List
 For ALL-WHEEL DRIVE (AWD) INDICATOR ALWAYS ON testing, go to appropriate GAUGES &
INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
 For DIFFERENTIAL LOCK INDICATOR INOPERATIVE testing, go to appropriate GAUGES &
INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
SCAN TOOL DIAGNOSTICS
NOTE: DO NOT use a scan tool that displays faulty data. The use of a faulty scan tool
can result in misdiagnosis and the unnecessary replacement of parts. Only the
parameters listed under SCAN TOOL DEFINITIONS are used in diagnosing. If a
scan tool displays other parameters, the values are not recommended by
General Motors for use in diagnosis.
Only use scan tool diagnostics under the following conditions:
 The Diagnostic System Check is complete.

 The on-board diagnostics are functioning properly.
 No DTCs are present.
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The values listed in AWD SCAN TOOL DATA LIST table represent a typical display recorded from a
properly functioning system, recorded under the following conditions:
 Engine at idle.
 Upper radiator hose hot.
 Closed throttle.
 Transmission in PARK.
 Closed Loop operation.
 Accessories OFF.
 Brake pedal not applied.
AWD SCAN TOOL DATA LIST

Scan Tool Parameter Data List Units Displayed Typical Data Value
AWD Circuit Status (1) OK/Short/Open OK
AWD Clutch temperature (1) Yes/No No
Disable
AWD Duty Cycle (1) Percent Varies
AWD Fluid temperature (1) Yes/No No
Disable
AWD Voltage Disable (1) Yes/No No
AWD Mini Spare Disable (1) Yes/No No
AWD Overtemperature (1) Yes/No No
Display
AWD Torque Management (1) Active/Inactive Inactive
AWD Wheel Speed (1) Yes/No No
Disable
Last Disable Reason (1) Fluid Temp, Clutch Varies
Temp, Wheel Speed,
Voltage, Mini Spare,
ABS System
Current Gear (1) (2) (3) (4) (5) (6) (7) 1, 2, 3, 4 1
ECT (1) (2) (3) °C (°F) Varies
Engine Speed (1) (2) (3) (4) (5) (6) (7) RPM 650-750 RPM
Engine Torque (1) (2) (3) N.m (Ft. Lbs.) Varies
Gear Ratio (1) (2) (3) (4) (5) (6) Ratio 3.98
Ignition Voltage (1) (2) Volts 12.5-15.5
TP Angle (1) (2) (3) (4) (5) (6) (7) Percent 0%
Trans. Fluid Temp. (1) (2) (3) (7) °C (°F) Varies
Transmission ISS (1) (2) (3) (4) (5) (6) RPM 600-700 RPM
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Transmission OSS (1) (2) (3) (4) (5) (6) RPM 0

Vehicle Speed (1) (2) (3) (4) (5) (6) MPH (KM/H) 0
(1) AWD data.
(2) Transmission data.
(3) TCC data.
(4) 1-2 Shift data.
(5) 2-3 Shift data.
(6) 3-4 Shift data.
(7) PC Solenoid data.
Scan Tool Data Definitions
AWD Circuit Status
Displays OK, Short or Open. This parameter indicates the status of the PWM signal line to the AWD
solenoid. The PCM can detect a short to ground, a short to power, or an open in the PWM signal line. The
AWD DISABLE light will be illuminated for Short and Open conditions.
AWD Clutch Temperature Disable
Displays Yes or No. This parameter displays the status of powertrain software that has the ability to
disable AWD based on a rear drive module clutch slip/time calculation. If the software determines that a
clutch over-temperature condition could exist, the PCM will deactivate the AWD system by disabling the
PWM signal line to the AWD solenoid. The AWD System will be re-enabled when the software
calculates that the clutch temperatures have dropped sufficiently. The AWD DISABLE light will be
illuminated for a YES condition.
AWD Duty Cycle
The All Wheel Drive (AWD) Duty Cycle parameter displays the commanded state of the AWD solenoid
expressed as a percent of ON time. At vehicle start-up, duty cycle will be at 75-90% for 3 seconds. This is
referred to as the pull-in duty cycle. After 3 seconds the duty cycle will drop to 20-30% for 30 seconds.
This is referred to as the hold-in duty cycle. After each 30 second hold-in period, the duty cycle will be
increased to 75-90%, pull-in duty cycle, for 0.5 second before returning to the hold-in duty cycle. This is
to assure solenoid pull-in.
AWD Fluid Temperature Disable
Displays YES or NO. This parameter indicates a fluid over-temperature condition in the rear drive
module. When the sump temperature exceeds approximately 230°F (110°C), a pull-up resistor grounds
the PWM signal line from the PCM at the AWD solenoid. The pull-up resistor is an integral part of the
AWD solenoid. The pull-up resistor will close the valve and command the PCM to illuminate the AWD
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DISABLE light for a YES condition. The scan tool will indicate a 100% duty cycle because the pull-up
resistor in the valve is bypassing the PCM.
AWD Voltage Disable
Displays YES or NO. This parameter indicates whether the ignition voltage to the AWD solenoid is in the
proper range. The ignition voltage range to the AWD solenoid is 9.0 to 16.0 volts. The PCM will
deactivate the AWD system by disabling the PWM signal line to the AWD solenoid if the ignition
voltage is out of range. The AWD DISABLE light will be illuminated for a YES condition.
AWD Mini Spare Disable
The All Wheel Drive (AWD) Mini spare Disable parameter indicates whether the ABS module detects a
mini spare on the vehicle and displays Yes or No. The wheel rotational speed difference is detected by the
wheel speed sensors of the ABS system. If the ABS module detects a mini spare on the vehicle, the PCM
will deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The AWD
Disabled lamp will be illuminated for a Yes condition.
AWD Overtemperature Delay
The All Wheel Drive (AWD) Overtemperature Delay parameter indicates whether the AWD system is in
a reset mode following an AWD fluid temperature disable and displays Yes or No. There is a 10 minute
delay from the time the rear drive module resistor closes the PWM signal line until the PCM again checks
the signal line for an overtemperature condition. The rear drive module resistor is an integral part of the
AWD solenoid. The AWD Disabled lamp will be illuminated for a Yes condition.
AWD Torque Management
Displays ACTIVE or INACTIVE. This is an indication that some form of torque management is being
performed to protect the AWD System. If either or both of these powertrain software features are
functioning, a service scan tool will display ACTIVE.
AWD Wheel Speed Disable
Displays Yes or No. This parameter indicates whether the wheel speed data received from the ABS
controller is valid. If the ABS module detects an unacceptable wheel speed differential, the PCM will
deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The AWD
DISABLE, BRAKE, and ANTI-LOCK Indicators, will be illuminated for a Yes condition. The chime
will also sound.
AWD DISABLE Mileage
Displays mileage. This parameter indicates the vehicle mileage at which the AWD Last Disable condition
occurred.
Current Gear
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Displays 1, 2, 3 or 4. This parameter indicates the current commanded state of the shift solenoid valves.
ECT (Engine Coolant Temperature)
The Engine Coolant Temperature (ECT) sensor is mounted in the coolant stream and sends engine
temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a
thermistor that changes internal resistance as temperature changes. When the sensor is cold, the internal
resistance is high, the PCM monitors a high signal voltage. The PCM interprets this voltage as a cold
engine. As the sensor warms, the internal resistance decreases, the voltage signal will decrease. The PCM
interprets the lower voltage as a warm engine.
Engine Speed
This parameter indicates the rotational speed of the engine expressed as revolutions per minute. The
engine speed is computed by the PCM from the fuel control reference input, the crankshaft position
sensor.
Engine Torque
This parameter indicates the amount of torque being delivered by the engine and is displayed in both
English and metric units.
Gear Ratio
This display is the actual transmission gear ratio as the transmission operates through all DRIVE,
REVERSE and PARK/NEUTRAL ranges.
Ignition Voltage
This parameter is the system voltage measured by the PCM at the PCM ignition input when the ignition
switch is in the RUN position.
Last Disable Reason
Displays only the last AWD DISABLE reason. The possible reasons are output controls, fluid temp,
clutch temp, wheel speed, voltage, mini spare or ABS System. The output controls reason indicates that
AWD was last disabled with a service scan tool. Fluid temp, clutch temp, wheel speed, voltage and mini
spare each have a unique parameter that is described elsewhere in this table. ABS system reason indicates
that messages normally sent to the PCM by the ABS controller are missing.
TP (Throttle Position) Angle
Displays 0-100%. The TP angle is computed by the PCM from the TP sensor voltage. The TP angle
should display 0% at idle and 100% at Wide Open Throttle (WOT).
Trans. Fluid Temp. (Transmission Fluid Temperature)
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The Transmission Fluid Temperature parameter displays the temperature conversion of the voltage input
signal to the PCM from the transmission fluid temperature (TFT) sensor. When the TFT is high 304°F
(151°C), the signal voltage is low, 0 volts. When the TFT is low -40°F (-40°C), the signal voltage is high,
5 volts.
Transmission ISS (Input Shaft Speed)
Displays 600-700 RPM. This parameter is the rotational speed of the transmission input shaft as
expressed in Revolutions Per Minute (RPM).
Transmission OSS (Output Shaft Speed)
Displays 0 RPM. This display indicates the rotational speed of the transmission output shaft as expressed
in Revolutions Per Minute (RPM).
Vehicle Speed
This parameter is the Vehicle Speed Sensor (VSS) input signal converted by the PCM to be displayed as
vehicle speed in both Metric and English units.
REMOVAL & INSTALLATION
NOTE: 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.
DIFFERENTIAL ASSEMBLY
Removal
1. Set the parking brake. Raise and support the vehicle. Remove the right rear tire/wheel assembly. Place a
drain pan beneath the differential. Remove the differential drain plug. See Fig. 1 . Drain the rear
differential gear oil. Disconnect the electrical connector from the clutch pump check valve. See Fig. 1 .
Remove the right rear axle shaft. See appropriate AXLE SHAFTS - REAR article in
DRIVELINE/AXLE. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL
JOINTS article in DRIVELINE/AXLE.
2. Place an adjustable support beneath the torque tube. Loosen, but DO NOT remove the torque tube-to-
bracket through-bolt and nut. Remove torque tube bracket-to-body bolts. Remove the differential carrier-
to-cradle mounting bolts, nuts, washers and mounts from the differential. During the removal of the axle
shaft, the differential output shaft may become disengaged from the differential. If this occurs, firmly
grasp and separate the output shaft from the axle shaft. Align the splines on the output shaft to the
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differential and reposition the output shaft to the differential.

3. While simultaneously moving the differential assembly to the right side of the vehicle, disengage the left
axle shaft from the differential. Remove the rear differential and torque tube as an assembly. Remove the
torque tube from the differential. See TORQUE TUBE ASSEMBLY .
Installation
1. Install the torque tube to the differential. See TORQUE TUBE ASSEMBLY . Install the rear differential
and torque tube assembly to the suspension cradle. Simultaneously guide the left axle shaft onto the
differential output shaft while positioning the differential assembly to the suspension cradle. Place an
adjustable support under the torque tube. Ensure that the left axle shaft is fully engaged to the differential
output shaft. Install the differential carrier mounts, washers, bolts and nuts to the differential.
2. Tighten the differential carrier-to-cradle mounting bolts to specification. See TORQUE
SPECIFICATIONS . Install the torque tube bracket-to-body bolts. Tighten the torque tube bracket-to-
body bolts to specification. See TORQUE SPECIFICATIONS . Tighten the torque tube-to-bracket
through-bolt and nut to specification. See TORQUE SPECIFICATIONS .
3. Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article under
DRIVELINE/AXLE. Install the right axle shaft. See appropriate AXLE SHAFTS - REAR article in
DRIVELINE/AXLE. Install the right rear tire and wheel assembly. Tighten bolts to specifications. See
TORQUE SPECIFICATIONS . Install the differential drain plug and gasket to the differential. Tighten
the drain plug to specification. See TORQUE SPECIFICATIONS .
4. Remove the differential fill plug. See Fig. 1 . Fill the axle with synthetic gear oil. Inspect the differential
oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. See
LUBRICATION . Fill differential as necessary. Install the differential fill plug and gasket. Tighten the
fill plug to specifications. See TORQUE SPECIFICATIONS .
5. Connect the electrical connector to the clutch pump check valve. Remove the adjustable support from the
torque tube. Lower the vehicle. Operate the vehicle making tight left, then right turns in order to engage
the all-wheel-drive system and distribute the gear oil throughout the differential. Raise and support the
vehicle. Remove the differential fill plug. Fill the axle with synthetic gear oil. Inspect the differential oil
level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. Install
the differential fill plug and gasket. Tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle.
DIFFERENTIAL CARRIER ASSEMBLY MOUNT
Removal
1. Raise and support the vehicle. Support the front of the differential with a suitable stand. Loosen, but do
not remove, the torque tube-to-bracket through bolt and nut. See Fig. 1 .
2. Remove the cradle-to-differential mounting bolts, nuts, washers, and bushings from the differential. See
Fig. 3 . Raise the stand slightly in order to gain access to the differential-to-cradle bushings. Remove the
differential-to-cradle bushings. See Fig. 3 .
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Fig. 3: Identifying Differential Mounting Bolts And Bushings

Courtesy of GENERAL MOTORS CORP.
Installation
1. Install the differential-to-cradle bushings. See Fig. 3 . Lower and remove the jack stand.
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2. Install the cradle-to-differential mounting bolts, bushings, washers, and nuts to the differential. Tighten
the bolts and nuts to specifications. See TORQUE SPECIFICATIONS .
3. Secure the torque tube-to-bracket through bolt and nut. Tighten the bolt and nut to specifications. See
TORQUE SPECIFICATIONS . Lower the vehicle.
DIFFERENTIAL CLUTCH PUMP CHECK VALVE
Removal
Drain the differential lubricant. See LUBRICATION . Disconnect the clutch pump check valve electrical
connector. Remove the clutch pump check valve mounting bolts. See Fig. 1 . Remove the clutch pump check
valve by carefully pulling straight out of the differential carrier. Remove the "O" ring seals from the valve. The
"O" ring seals may be reused if not cut or damaged. If reinstalling original valve, inspect for damaged, loose, or
missing pick up screen, damaged or missing "O" rings, damaged electrical connector, or oil passages restricted
by dirt or debris.
Installation
NOTE: Inspect the clutch pump check valve "O" ring seals to ensure they are not cut
or damaged. Replace cut or damaged "O" ring seals with NEW seals.
1. Lubricate the "O" ring seals with Synthetic Gear Oil (12378514 for United States or 88901045 for
Canada) or equivalent. Install the "O" ring seals to the valve. Install the clutch pump check valve to the
differential carrier by carefully pushing the valve straight in until fully seated.
2. Install the clutch pump check valve mounting bolts. See Fig. 1 . Tighten the bolts to specification. See
TORQUE SPECIFICATIONS . Connect the clutch pump check valve electrical connector. Inspect
differential fluid level. See LUBRICATION . Fill differential as necessary.
DRIVE PINION FLANGE/YOKE &/OR OIL SEAL
Removal
NOTE: The internal components of the torque tube assembly cannot be serviced
separately. If corrosion exists that cannot be polished off, or there is excessive
scoring or wear, the torque tube must be replaced as a complete assembly.
Drain differential. Remove the torque tube assembly. See TORQUE TUBE ASSEMBLY . Remove the drive
pinion housing oil seal, and discard. See Fig. 1 . Inspect the sealing surface of the drive shaft contained inside
the torque tube. Polish corrosion off with a crocus cloth.
Installation
NOTE: Required Tools: Seal Installer (J-44915).
Lubricate the NEW pinion housing assembly "O" ring and oil seal with Synthetic Gear Oil (12378514 for
Toshiba
2003 Pontiac Aztek
United States; 88901045 for Canada) or equivalent. Use the Seal Installer in order to install the NEW oil seal to
the drive pinion housing. Install the torque tube assembly. See TORQUE TUBE ASSEMBLY . Tighten bolts
to specification. See TORQUE SPECIFICATIONS . Inspect the differential carrier lubricant level. See
LUBRICATION .
DRIVE PINION HOUSING AND/OR SEAL
Removal
1. Drain the differential lubricant. See LUBRICATION . Remove the torque tube assembly. See TORQUE
TUBE ASSEMBLY . Remove the drive pinion oil seal from the drive pinion housing and discard. See
Fig. 1 .
2. Remove the pinion housing-to-differential bolts. Remove the drive pinion and housing assembly.
Carefully remove the drive pinion housing shim from the differential. See Fig. 1 .
3. Remove the O-ring seal from the drive pinion housing and discard.
Installation
1. Lubricate the O-ring seal with synthetic gear oil GM P/N United States 12378514 Canada P/N 88901045
or equivalent. Using the Seal Installer, install the oil seal to the drive pinion housing. Install the O-ring
seal to the drive pinion housing.
2. Carefully install the drive pinion housing assembly and shim to the differential carrier. See Fig. 1 . Install
the pinion housing-to-differential mounting bolts. Tighten the bolts specifications. See TORQUE
SPECIFICATIONS .
3. Lubricate the sealing surfaces of the drive pinion oil seal with synthetic gear oil GM P/N United States
12378514 Canada P/N 88901045 or equivalent. Install the torque tube assembly. See TORQUE TUBE
ASSEMBLY . Fill the differential with synthetic gear oil. See LUBRICATION .
REAR AXLE SHAFT SEALS
Removal & Installation
NOTE: Required Tools: Output Shaft Seal Installer (J-44809).
NOTE: Inspect the sealing surface of the axle shaft inner tri-pot housing to ensure it is
free of corrosion. Use a crocus cloth in order to remove any light corrosion and
clean the sealing surface with denatured alcohol, or equivalent.
Raise and support the vehicle. Remove the left rear or right rear tire and wheel assembly. Remove the left axle
shaft or right axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Remove
the differential output shaft oil seal. See Fig. 1 . Do not damage the differential sealing surfaces. Using the
Output Shaft Seal Installer, install the left or right axle shaft oil seal. Lubricate the axle shaft sealing surfaces of
the oil seal with synthetic gear oil GM P/N 12378514 Canadian P/N 88901045 or equivalent. Install the right or
Toshiba
2003 Pontiac Aztek
left axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Install the right or
left rear tire and wheel assembly. Tighten bolts to specifications. See TORQUE SPECIFICATIONS . Inspect
the differential lubricant level. See LUBRICATION . Lower the vehicle.
TORQUE TUBE ASSEMBLY
Removal
NOTE: The drive pinion oil seal must be replaced whenever the torque tube is
removed.
1. Raise and support the vehicle. Position a jack stand under the front of the rear differential and firmly
secure the differential to the jack. Remove the front drive shaft. See appropriate DRIVE SHAFT &
UNIVERSAL JOINTS article under DRIVELINE/AXLE.
2. Remove the bolts from the torque tube bracket. See Fig. 1 . Loosen, but DO NOT remove, the torque
tube-to-bracket through-bolt and nut. Remove the torque tube-to-differential bolts. Pull the torque tube
toward the front of the vehicle in order to disengage the torque tube from the differential pinion shaft.
Remove the torque tube from the differential. Remove the oil seal from the drive pinion housing and
discard.
Installation
1. Using Seal Installer, install a NEW oil seal to the drive pinion housing. See Fig. 1 . Align the splines on
the torque tube shaft to the differential pinion shaft. Install the torque tube to the differential.
2. Install the bolts to the torque tube bracket. Tighten the torque tube bracket bolts to specification. See
TORQUE SPECIFICATIONS . Tighten the torque tube-to-bracket through-bolt and nut to
specification. Install the torque tube-to-differential carrier bolts. Tighten the bolts to specification. See
TORQUE SPECIFICATIONS .
3. Install the front drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article under
DRIVELINE/AXLES. Tighten the mounting bolts to specification. See TORQUE SPECIFICATIONS .
Remove the jack stand from under the front of the rear differential. Lower the vehicle.
TORQUE TUBE MOUNTING BRACKET
Removal
Raise and support the vehicle. Place a jack stand under the torque tube. Remove the torque tube-to-bracket
through-bolt, nut, washers and spacers. Remove the torque tube bracket-to-body bolts. See Fig. 1 . Lower the
jack stand slightly in order to gain access to the torque tube bracket. Remove the torque tube-to-bracket through
bolt, nut, washers, and spacers. Remove the torque tube bracket.
Installation
Toshiba
2003 Pontiac Aztek
NOTE: DO NOT fully tighten the torque tube-to-bracket through-bolt. Hand tighten only
until the bracket is secured to the vehicle body.
1. Install the torque tube bracket. Install the torque tube-to-bracket through-bolt, nut, washers and spacers.
Raise the jack stand in order to install the torque tube mounting bracket to the vehicle body.
2. Install the torque tube bracket-to-body bolts. Tighten the torque tube mounting bracket-to-body bolts to
specification. Tighten the torque tube-to-bracket through-bolt to specification. See TORQUE
SPECIFICATIONS . Remove the jack stand. Lower the vehicle.
VENT HOSE
Removal & Installation
Raise and support the vehicle. Remove the vent hose clamp from the vent hose. Release the grommet securing
the vent hose to the vehicle underbody. Remove the vent hose from the differential assembly vent tube by
carefully twisting the hose. See Fig. 1 . Install the vent hose to the differential assembly. Install the vent hose
clamp to the vent hose. Secure the grommet on the vent hose to the vehicle underbody. Lower the vehicle.
OVERHAUL
DIFFERENTIAL ASSEMBLY
Disassembly
NOTE: Do not disassemble the side cover or differential assembly. Oil seal damage or
the entry of foreign material into the hydraulic system may effect system
operation.
1. Remove the lubricant drain plug and gasket from the differential. See Fig. 1 . Allow the lubricant to drain.
Remove vent hose assembly and clamp. See VENT HOSE . Remove clutch pump check valve. Remove
"O" rings from check valve. The O-ring seals may be reused if not cut or damaged.
NOTE: Do not remove the dampeners from the torque tube. Removal and
reinstallation may effect component noise and/or vibration levels.
2. Remove torque tube bracket nut, bolt and spacers. Remove torque tube bracket. See Fig. 1 . Remove
torque tube-to-differential bolts. Separate torque tube from differential. Remove bolts from differential.
3. Remove pinion housing and shim. Remove oil seal and "O" ring from pinion housing. Remove left and
right axle shaft oil seals. See REAR AXLE SHAFT SEALS .
Differential Inspection
Inspect the differential for the following:
 A damaged or restricted vent tube.

Toshiba
2003 Pontiac Aztek
 Damaged oil seal bores.

 Damaged clutch pump check valve bore or bolt threads.
 Worn or scored pinion housing bore.
 Damage to the exterior of the differential.
 Damaged axle shaft splines and/or missing axle shaft snap rings.
Rotate the pinion shaft by hand. The shaft should rotate with minimal resistance and no coarse or rough feeling.
If shaft rotation is not as described, inspect the pinion and housing assembly for the following:
 Worn or damaged splines.

 Abnormal pinion gear tooth wear.
 Damaged pinion housing "O" ring seal groove.
 Damaged oil seal and Worn bearings.
Reassembly
NOTE: Required Tools: Seal Installer (J-44809) and Output Shaft Seal Installer (J-
44809).
1. Using the Seal Installer, install left and right axle shaft oil seals. See REAR AXLE SHAFT SEALS .
Lubricate "O" ring seal with Lubricate the O-ring seal and oil seal sealing surface with gear oil GM P/N
12378514 (Canadian P/N 88901045). Install NEW "O" ring into groove of pinion housing. Using Seal
Installer, install oil seal into pinion housing.
2. Install pinion housing assembly and shim into differential. Install and tighten differential bolts to
specification. See TORQUE SPECIFICATIONS . Install torque tube onto differential. See TORQUE
TUBE ASSEMBLY . Install torque tube bracket nut and bolt. Install spacers to tube flange. Install the
bracket, bolt, washers and nut to the tube.
3. Install the O-ring seals onto the clutch pump check valve. Install the valve and bolts to the differential.
Tighten the valve bolts to specification. See TORQUE SPECIFICATIONS . Install the vent hose
assembly and clamp to the differential. Install the oil drain plug and gasket to the differential. Tighten the
drain plug to specification. See TORQUE SPECIFICATIONS .
SERVICING
DIFFERENTIAL CLUTCH PUMP CHECK VALVE CLEANING AND INSPECTION
Inspect the inlet valve for the following:
 Damaged, loose, or missing pick up screen.

 Damaged or missing O-rings.
 Damaged electrical connector.
 Oil passages restricted by dirt or debris.
Toshiba
2003 Pontiac Aztek
TORQUE TUBE ASSEMBLY CLEANING AND INSPECTION
NOTE: The internal components of the torque tube assembly are not serviced
separately. Replace the tube and internal components as an assembly.
1. Inspect the torque tube for broken or cracked welds, dents or damage to the exterior of the tube, a
damaged propeller shaft flange, or loose or missing dampeners.
2. Inspect the propeller shaft seal surface for wear or excessive scoring. Inspect the propeller shaft splines
for any unusual or excessive wear.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Axle Shaft Nut 192 (260)
Brake Caliper Bolts 33 (45)
Brake Caliper Bracket Bolts 96 (130)
Dampener Bolt 47 (64)
Differential Carrier-To-Cradle Mount Bolts 37 (50)
Differential Drain & Fill Plugs 23 (32)
Drive Shaft-To-Transfer Case & Torque Tube Flange Bolt (8 mm) 24 (33)
Drive Shaft To Torque Tube Bolts 24 (33)
Rear Suspension Knuckle Bolt & Nut 63 (85)
Rear Tie Rod Bolt 63 (85)
Seal Clamps - Large & Small 100 (136)
Suspension Knuckle-To-Control Arm Bolt 63 (85)
Tie Rod Bolt 63 (85)
Torque Tube Bracket-To-Body Bolts 41 (56)
Torque Tube Bracket Through-Bolt & Nut 47 (64)
Torque Tube-To-Differential Bolts 18 (25)
Upper Control Arm Knuckle Bolts 63 (85)
Wheel Lug Nuts 100 (140)
INCH lbs. (N.m)
Clutch Pump Check Valve Bolts 106 (12)
Parking Brake Cable Bracket 89 (10)
Pinion Housing-To-Differential Bolts 106 (12)
Valve Bolts 106 (12)
Wheel Nut Caps 27 (3)
WIRING DIAGRAMS
Toshiba
2003 Pontiac Aztek
NOTE: Go to SYSTEM WIRING DIAGRAMS under ELECTRICAL.
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2003 Pontiac Aztek

2003 DRIVE AXLES Differential - Aztek & Rendezvous

2003 DRIVE AXLES

Differential - Aztek & Rendezvous

DESCRIPTION & OPERATION

DIFFERENTIAL LOCK SYSTEM

AWD DISABLE indicator

Differential Clutch Pump Actuator Check Valve

Powertrain Control Module

Fig. 1: Exploded View Of Rear Axle Shaft & Differential

Fig. 2: Identifying Differential Components

DIAGNOSTIC STARTING POINT - REAR AXLE CONTROLS

 The Identification of the control module(s) which command the system.

DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS

NOTE: This step determines if a DTC is current or stored in history.

SYMPTOMS - REAR DIFFERENTIAL CARRIER

NOTE: For noise concerns, see TROUBLE SHOOTING in VIBRATION - DRIVETRAIN

SYMPTOMS - REAR AXLE CONTROLS

SCAN TOOL DIAGNOSTICS

Only use scan tool diagnostics under the following conditions:

 The Diagnostic System Check is complete.

AWD SCAN TOOL DATA LIST

Transmission OSS (1) (2) (3) (4) (5) (6) RPM 0

Scan Tool Data Definitions

AWD Circuit Status

AWD Clutch Temperature Disable

AWD Duty Cycle

AWD Fluid Temperature Disable

AWD Voltage Disable

AWD Mini Spare Disable

AWD Overtemperature Delay

AWD Torque Management

AWD Wheel Speed Disable

AWD DISABLE Mileage

ECT (Engine Coolant Temperature)

Last Disable Reason

TP (Throttle Position) Angle

Trans. Fluid Temp. (Transmission Fluid Temperature)

Transmission ISS (Input Shaft Speed)

Transmission OSS (Output Shaft Speed)

REMOVAL & INSTALLATION

differential and reposition the output shaft to the differential.

DIFFERENTIAL CARRIER ASSEMBLY MOUNT

Fig. 3: Identifying Differential Mounting Bolts And Bushings

DIFFERENTIAL CLUTCH PUMP CHECK VALVE

DRIVE PINION FLANGE/YOKE &/OR OIL SEAL

NOTE: Required Tools: Seal Installer (J-44915).

DRIVE PINION HOUSING AND/OR SEAL

NOTE: Required Tools: Seal Installer (J-44915).

REAR AXLE SHAFT SEALS

Removal & Installation

NOTE: Required Tools: Output Shaft Seal Installer (J-44809).

TORQUE TUBE ASSEMBLY

NOTE: Required Tools: Seal Installer (J-44915).

TORQUE TUBE MOUNTING BRACKET

Removal & Installation

Inspect the differential for the following:

 A damaged or restricted vent tube.

 Damaged oil seal bores.

 Worn or damaged splines.

Inspect the inlet valve for the following:

 Damaged, loose, or missing pick up screen.

TORQUE TUBE ASSEMBLY CLEANING AND INSPECTION