NHTSA ID Number: 11009768
Manufacturer Communication Number: 24-DS-001G-1 TSB
TSB/Document Date: 2024-11-05
Summary
Certain GV70 (JK1, JK1A), GV80 (JX1) and G80 (RG3) vehicles may have a hum or whine noise condition from the rear differential at certain speeds. This bulletin describes the procedure to inspect the vehicle for the hum or whine noise and if necessary to tighten the rear differential lock nut first. If the hum or whine noise remains, then replace the rear differential or other driveline components as necessary.
SUBJECT:
4.
Note the direction of bolts (C), washers (RG3
only), and nuts (D) before removing the
propeller shaft
(E) from the transfer
case/transmission and rear differential flange
(F).
Propeller Shaft to Flange* Tightening
Torque
lb-ft
73
N.m
99
E
D
F
*Transfer case/transmission and rear
differential flanges
C
Transfer Case Flange/Propeller Shaft
Note the alignment of the yellow dot (G) on the
transfer case/transmission and rear differential
flange and the red stripe (H) on the propeller
shaft rubber coupling.
If the dot or the stripe are NOT visible, create
similar markings before disassembly to ensure
the position of the propeller shaft to the flanges
during reassembly.
NOTICE
•
G
Installing the bolts, washers (RG3 only),
and nuts differently from the initial state
or changing the position of the propeller
shaft relative to the flange can result in
unbalanced propeller shaft causing a
vibration at high speed.
•
Properly support the entire length of the
propeller shaft after it is removed.
I.e., place it on level ground.
•
Do NOT reuse the bolts and nuts during
reinstallation of the propeller shaft to
the flanges.
TSB #: 24-DS-001G-1
H
During reassembly, align the dot (G) on the
flange with the stripe (H) on the propeller
shaft rubber coupler.
Page 10 of 20
SUBJECT:
5.
After removal of the propeller shaft, using
STUI, take a photo of the rear differential lock
nut.
STUI
Using STUI, take a photo before
tightening the lock nut, the last 6
digits of the VIN, and the date of repair
on a piece of paper.
Upload the photos to STUI.
6.
7.
Locate the stake (I) on the lock nut in the
differential flange.
I
Mark a line (J) on the located stake up to the
threads on the shaft.
J
TSB #: 24-DS-001G-1
Page 11 of 20
SUBJECT:
8.
Mark a second line that is 6.7 mm to the left of
the first.
2
1
TSB #: 24-DS-001G-1
Page 12 of 20
SUBJECT:
9.
Tighten the lock nut using a 1/2-inch impact
wrench with a 30 mm deep socket.
i
Tightening Range
Information
The 1/2-inch impact wrench must
provide enough torque to turn the lock
nut.
Tighten the lock nut incrementally. Check the
movement of the mark every 1-2 seconds.
Stop when the nut reaches the 6.7 mm mark
or 30° of rotation.
Tightening Range:
Minimum: 4.5 mm, 20°
Target: 6.7 mm, 30°
Maximum: 13.3 mm, 60°
NOTICE
•
Ensure the impact wrench is in the
tightening, clockwise direction.
•
Do NOT tighten the nut beyond 60°
of rotation. If the nut is over
tightened, replace the differential.
•
Do NOT loosen the nut and attempt
to retighten the nut. If the nut is
loosened, the differential must be
replaced.
•
If the nut does NOT reach at least 20°
of rotation, replace the differential.
Alignment of the 2 marks indicates the nut
tightened to the target 30°.
If differential replacement is necessary,
refer to the procedures in Rear
Differential Replacement below.
TSB #: 24-DS-001G-1
Page 13 of 20
SUBJECT:
10.
STUI
Using STUI, take a photo after
tightening the lock nut with the marks
clearly visible, the last 6 digits of the
VIN, and the date of repair on a piece
of paper.
Upload the photos to STUI.
i
Information
A photo is required regardless of the nut
tightening angle.
TSB #: 24-DS-001G-1
Page 14 of 20
SUBJECT:
11.
Install parts in the reverse order of removal.
Refer to the applicable shop manual for
tightening torque specificaitons.
K
L
NOTICE
The following new parts must be used
during reassembly. Use the above Parts
Information table, shop manual, and
parts catalog to ensure the correct parts
are used:
•
•
•
•
•
Propeller shaft to
transmission/
transfer case
Propeller Shaft Bolts (K)
(to transmission/ transfer case)
Propeller Shaft Nuts (K)
(to transmission/ transfer case)
Propeller Shaft Bolts (L)
(to differential)
Front Exhaust Gasket (M) (to catalyst)
Rear Exhaust Gasket (N)
(to exhaust muffler)
Propeller shaft to
rear differential
N
M
Reusing parts will NOT provide the
correct clamping force and can cause the
exhaust to leak.
Ensure proper propeller shaft alignment and
fastener locations as noted in step 4 above.
Install the propeller shaft in the following order:
A. Flange to transmission/transfer case
B. Center bearing bracket
C. Flange to rear differential
TSB #: 24-DS-001G-1
1
2
3
Front
Page 15 of 20
SUBJECT:
12.
After reassembly, drive the vehicle on the road to inspect the vehicle for rear differential noise.
•
GV70 (JK1,JK1A): Hum or whine noise in the speed range of 37 to 70 mph
(approx. 60 to 110 km/h)
o To confirm the noise is from the rear differential, drive at approximately 52 mph
and gently depress the accelerator pedal then release the pedal to coast. Repeat
this a few times. The humming/whining noise will be most apparent when
depressing and releasing the pedal.
•
GV80 (JX1) and G80 (RG3): Hum or whine noise in the speed range of 25 to 50 mph
(approx. 80 to 40 km/h)
o To confirm the noise is from the rear differential, drive at approximately 35 mph
and gently depress the accelerator pedal then release the pedal to coast. Repeat
this a few times. The humming/whining noise will be most apparent when
depressing and releasing the pedal.
i
•
•
•
•
•
•
•
Information
The noise does NOT have to occur during the entire speed range.
Do NOT test the vehicle for noise on the lift. The vehicle must be driven to accurately
assess for differentiall noise.
For an optimal evaluation, ensure a person sits in the rear seat during the test drive to
identify the noise source.
If the noise is NOT from the rear of the vehicle, then the rear differential may NOT be the
source. Determine where noise is coming from and proceed with diagnosis and repair for
that noise.
If the noise as described above is heard, replace the differential. Refer to the procedures in
Rear Differential Replacement below.
If the noise as described above is NOT heard, the service procedure is now complete.
If other noises are heard from other areas of the vehicle, continue to diagnose, and repair
the vehicle as necessary.
TSB #: 24-DS-001G-1
Page 16 of 20
SUBJECT:
1.
Follow steps 1 to 4 in the Rear Differential
Lock Nut Tightening procedures to remove
the propeller shaft again.
2.
to remove and install the new rear differential,
Refer to the applicable shop manual:
• Driveshaft and Axle > Differential
Carrier Assembly > Rear Differential
Carrier
If the vehicle is equipped with an E-LSD,
remove it before removing the differential.
Refer to the shop manual:
• Electronic Limited Slip Differential
System > Electronic Limited Slip
Differential (E-LSD)
3.
STUI
Using STUI, take a photo of the new
rear differential next to the removed
differential with the differential labels
(H) visible, the last 6 digits of the VIN,
and the date of repair on a piece of
paper.
H
Upload the photos to STUI.
TSB #: 24-DS-001G-1
Page 17 of 20
SUBJECT:
4.
After reinstalling the rear differential carrier,
use a feeler gauge to ensure there is a gap of
less than 0.04 mm between the rear differential
carrier cover and the bushing protrusion.
If the gap is larger than 0.04 mm, the
differential carrier and the bushing may NOT
be aligned properly. Loosen the bolts to align
the differential, then torque the bolts to
specification.
NOTICE
•
New differentials from the Parts Distribution Center (PDC) are not filled with gear oil.
•
Fill with the gear oil until it reaches the fill port.
•
Failure to fill the differential with gear oil will damage the differential and may result in a
warranty charge back.
5.
Fill the differential with gear oil.
GV70
(JK1,
JK1A)
GV80
(JX1)
G80
(RG3)
1.2 +/- 0.05 L
(1.27 +/- 0.05 qt)
1.3 +/- 0.05 L
(1.37 +/- 0.05 qt)
1.2 +/- 0.05 L
(1.27 +/- 0.05 qt)
75W-85 LSD*
P/N: 00232-19075
75W-85 Non LSD
P/N: 00232-19097
*LSD gear oil designates the specification,
NOT if the vehicle is equipped with an E-LSD.
Ensure the gear oil reaches the fill port.
TSB #: 24-DS-001G-1
Page 18 of 20
SUBJECT:
6.
Install the remaining parts in the reverse order
of removal.
Refer to the applicable shop manual for
tightening torque specificaitons.
K
L
NOTICE
The following new parts must be used
during reassembly. Use the above Parts
Information table, shop manual, and
parts catalog to ensure the correct parts
are used.
•
•
•
•
•
•
•
Propeller shaft to
transmission/
transfer case
Propeller Shaft Bolts (K)
(to transmission/
transfer case)
Propeller Shaft Nuts (K)
(to transmission/
transfer case)
Propeller Shaft Bolts (L)
(to differential)
Front Exhaust Gasket (M) (to catalyst)
Rear Exhaust Gasket (N)
(to exhaust muffler)
Axle Clips (O)
Castle Lock Nuts (P)
Propeller shaft to
rear differential
N
M
O
P
Reusing parts will NOT provide the
correct clamping force and can cause the
exhaust to leak.
Ensure proper propeller shaft alignment and
fastener locations as noted in step 4 in the
Rear Differential Lock Nut Tightening
procedures.
Install the propeller shaft in the following
order.
A. Flange to transmission/transfer case
B. Center bearing bracket
C. Flange to rear differential
7.
2
1
3
Front
Perform a suspension alignment on an
alignment rack.
TSB #: 24-DS-001G-1
Page 19 of 20
SUBJECT:
8.
After reassembly, drive the vehicle on the road to inspect the vehicle for rear differential noise.
•
GV70 (JK1, JK1A): Hum or whine noise in the speed range of 37 to 70 mph
(approx. 60 to 110 km/h)
o To confirm the noise is from the rear differential, drive at approximately 52 mph
and gently depress the accelerator pedal then release the pedal to coast. Repeat
this a few times. The humming/whining noise will be most apparent when
depressing and releasing the pedal.
•
GV80 (JX1) and G80 (RG3): Hum or whine noise in the speed range of 25 to 50 mph
(approx. 80 to 40 km/h)
o To confirm the noise is from the rear differential, drive at approximately 35 mph
and gently depress the accelerator pedal then release the pedal to coast. Repeat
this a few times. The humming/whining noise will be most apparent when
depressing and releasing the pedal.
i
•
•
•
•
•
•
Information
The noise does NOT have to occur during the entire speed range.
Do NOT test the vehicle for noise on the lift. The vehicle must be driven to accurately
assess for differentiall noise.
For an optimal evaluation, ensure a person sits in the rear seat during the test drive to
identify the noise source.
If the noise is NOT from the rear of the vehicle, then the rear differential may NOT be the
source. Determine where noise is coming from and proceed with diagnosis and repair for
that noise.
If the noise as described above is NOT heard, the service procedure is now complete.
If other noises are heard from other areas of the vehicle, continue to diagnose, and repair
the vehicle as necessary.
NOTICE
Do NOT tighten the lock nut on a new differential.
TSB #: 24-DS-001G-1
Page 20 of 20
SUBJECT:
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TSB/Document ID: 24-DS-001G-1 TSB
Replacement Service Bulletin Number:
MFR Communication Date: 2024-10-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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