Drivetrain - Rear Differential Clunking Noise

Date: July 28, 2008

Order No.: P-B-35.31/05

Supersedes:

Group: 35

SUBJECT:
Model 171.454/456
Model 204.054/056/081
Model 211.022/056/072/087/090

Vehicles Produced Between 2/21/08 and 4/3/08 with Differential Serial Number 1824214 to 1865328

Clunking Noise During Load Change at Rear Axle Differential








If you receive customer reports in the above model vehicles of a clunking noise at the rear differential, the cause may be that the hardening process of the pinion gear in select vehicles was not optimized (production dates between February 21st and April 3rd 2008 or between differential serials numbers from 1824214 to 1865328 (Figure 1). To resolve, check if the rear differential oil is very gray/thick/viscous (Figure 2) and if the play at the outside of the of the rear axle differential flange (detach propeller shaft at differential end beforehand) is greater than 5 degrees, if so replace the rear axle differential. If excessive free-play is not identified in the differential flange, then the vehicle drive train should be carefully inspected to identify the source of the sound. Refer to EPCnet by VIN (Group 35/015) for the applicable part no.

Refer to following WIS documents:

^ AR35.31-P-0520v - Model 171

^ AR35.31-P-0520cw - Model 204

^ AR35.31-P-0520t - Model 211

Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on July 28, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.





In Case of Warranty, use the table.