23-DS-004G-1

DRIVESHAFT AND
AXLE
23-DS-004G-1
OCTOBER 2023
GV70 (JK1)
GV80 (JX1)
G80 (RG3)
REAR DIFFERENTIAL NOISE INSPECTION AND REPAIR
This TSB supersedes 23-DS-004G to update the rear propeller shaft bolt (to differential) part
number from 49319-T6100 to 49319-T6000.
Description: Certain GV70 (JK1 and JK1A), GV80 (JX1) and G80 (RG3) vehicles may have a noise
condition from the rear differential at certain speeds while accelerating or decelerating. This bulletin
describes the procedure to inspect the vehicle for noise and if necessary to tighten the lock nut or if
necessary replace the differential.
Applicable Vehicles:
• GV70 (JK1, VIN starts with "KMU") 2022MY ~
• GV70 (JK1A, VIN starts with "5NM") 2024MY ~
• GV80 (JX1) 2021MY ~
• G80 (RG3) 2021MY ~
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
Table of Contents
Parts Information: .............................................................................................. 2
Warranty Information: ........................................................................................ 4
Service Procedure: ............................................................................................. 5
Repair Flow Chart ........................................................................................... 5
Rear Differential Noise Inspection ................................................................ 6
Rear Differential Lock Nut Tightening........................................................... 6
Rear Differential Replacement ..................................................................... 14
Parts Information:
“JK1” refers to both JK1 (Korean) and JK1A (USA).
JK1
JX1
RG3
28751-3J000
JK1
JX1
28751-2S000
RG3
28751-3S100
JK1
JX1
49319-T6100
RG3
49319-3M000
JK1
JX1
RG3
49329-3M000
Front & Center
Muffler Gasket
2.5T: 1 each
3.5T: 2 each
Rear & Center
Muffler Gasket
2 each
2.5T and 3.5T
2 each
Rear Propeller Shaft Bolts
(to transfer case)
3 each
Rear Propeller Shaft Nuts
(to transfer case)
3 each
2.5T and 3.5T
JK1
JX1
49319-T6000
RG3
49319-T1000
Rear Propeller Shaft Bolts
(to differential)
3 each
Order the following parts only if differential replacement is necessary.
JK1
53000-47520
2.5T, AWD
53000-4J510
3.5T, AWD
53000-4J520
3.5T, AWD,
w/ & w/out E-LSD
53000-4J600
JX1
Rear Differential Carrier
2.5T, RWD & AWD
53000-4J620
2.5T, AWD, E-LSD
53000-4J610
3.5T, AWD
53000-4J630
3.5T, AWD, E-LSD
TSB #: 23-DS-004G-1
1 each
Page 2 of 17
SUBJECT:
53000-47501
RG3
53000-47502
2.5T, RWD
Rear Differential Carrier
53000-4J500
JK1
JX1
RG3
28751-3J000
JK1
JX1
28751-2S000
RG3
28751-3S100
JK1
JX1
49319-T6100
RG3
49319-3M000
JK1
JX1
RG3
49329-3M000
JK1
JX1
49319-T6000
RG3
49319-T1000
JK1
3.5T, RWD & AWD
Front & Center
Muffler Gasket
Rear & Center
Muffler Gasket
2.5T: 1 each
3.5T: 2 each
2 each
2.5T and 3.5T
2 each
Rear Propeller Shaft Bolts
(to transfer case)
3 each
Rear Propeller Shaft Nuts
(to transfer case)
3 each
Rear Propeller Shaft Bolts
(to differential)
3 each
49557-3M000
2.5T, w/out E-LSD
49557-2G000
3.5T, w/out E-LSD
49557-T6000
3.5T w/ E-LSD
JX1
Axle Clip
2.5T and 3.5T
w/out E-LSD
49557-T6000
2.5T and 3.5T
w/ E-LSD
49557-3M000
2.5T
49557-2G000
3.5T
JK1
JX1
RG3
49551-4T000
Axle Castle Lock Nut
JK1
JX1
00232-19075
Gear Oil, 75W-85, GL-5,
LSD*, 1.0qt
00232-19097
Gear Oil, 75W-85, GL-5,
Non LSD, 1.0qt
RG3
1 each
2.5T and 3.5T
49557-2G000
RG3
2.5T, RWD
2 each
2.5T and 3.5T
2 each
2.5T and 3.5T
2 each
*NOTE: LSD gear oil designates the specification, not if the vehicle is equipped with an E-LSD.
TSB #: 23-DS-004G-1
Page 3 of 17
SUBJECT:
Warranty Information:
GV70 (JK1
and JK1A)
GV80 (JX1)
G80 (RG3)
GV70 (JK1
and JK1A)
GV80 (JX1)
G80 (RG3)
GV70 (JK1
and JK1A)
GV80 (JX1)
GV70 (JK1
and JK1A)
GV80 (JX1)
G80 (RG3)
GV70 (JK1
and JK1A)
GV80 (JX1)
53000F08
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION
0.4 M/H
53000F09
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION, LOCK NUT
TIGHTENING, AND NOISE
REINSPECTION
1.9 M/H
53000F10
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION, LOCK NUT
TIGHTENING (WHEN
OVERTIGHTENED),
REPLACEMENT (WITHOUT ELSD), AND ALIGNMENT
4.7 M/H
53000F11
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION, LOCK NUT
TIGHTENING (WHEN
OVERTIGHTENED),
REPLACEMENT (WITH E-LSD)
AND ALIGNMENT
4.8 M/H
53000F12
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION, LOCK NUT
TIGHTENING, NOISE
REINSPECTION, REPLACEMENT
(WITHOUT E-LSD), AND
ALIGNMENT
6.1 M/H
53000F13
REAR DIFFERENTIAL CARRIER
NOISE INSPECTION, LOCK NUT
TIGHTENING, NOISE
REINSPECTION, REPLACEMENT
(WITH E-LSD), AND ALIGNMENT
6.2 M/H
53000*
Q26
ZZ1
NOTE 1: Normal warranty applies.
NOTE 2: Submit claim on Claim Entry Screen as “Warranty” type.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and Repair
validation photos as outlined in the Digital Documentation Policy
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 5: * Refer to applicable parts catalog for full causal part numbers.
TSB #: 23-DS-004G-1
Page 4 of 17
SUBJECT:
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Digital Documentation Policy for
requirements.
Repair Flow Chart
i
Information
In the following procedures, “JK1” refers to both JK1 (Korean) and JK1A (USA).
TSB #: 23-DS-004G-1
Page 5 of 17
SUBJECT:
Rear Differential Noise Inspection
1.
Drive the vehicle to inspect the vehicle for the
rear differential noise.
•
JK1: Whine noise while gradually
accelerating, in the speed range of 37 to
70mph (approx. 60 to 110 kph)
JX1 and RG3: Whine noise while coasting,
off throttle, in the speed range of 50 to 25mph
(approx. 80 to 40 kph)
•
i
Information
The noise does not have to occur during the
entire speed range.
If the noise is not heard, the service procedure is
now complete.
If the noise as described above is heard,
continue to the Rear Differential Lock Nut
Tightening procedure below.
If other noises are heard, continue to diagnose,
and repair the vehicle as necessary.
Rear Differential Lock Nut Tightening
1.
Using a lift, slightly raise the vehicle until the tires
are no longer touching the ground.
Within 3 minutes of turning off the vehicle’s
engine, place the transmission into neutral by
pressing the button (B) under the cap cover (A)
on the center console.
a) Remove the cap-cover.
b) Press the button while depressing the
brake pedal until the transmission shifts
into neutral. The button must be pressed
within 3 minutes after the engine is turned
off.
i
A
B
Information
If neutral is selected while the engine is
running, the transmission will not remain in
neutral when the vehicle is turned off.
TSB #: 23-DS-004G-1
Page 6 of 17
SUBJECT:
2.
If the vehicle is equipped with an E-LSD, use the
GDS “Brake Pad Change Mode” function to
release the parking brake.
The Brake Pad Change Mode procedures can be
found in the shop manual.
•
•
•
JK1: Brake System → Brake System →
Parking Brake System → Electronic Parking
Brake (EPB) → Adjustment
JX1 and RG3: Brake System → Brake
System → Rear Disc Brake → Repair
Procedures
After releasing the parking brake, disconnect
the 12v battery negative (-) terminal and the
EPB actuator connector after completing the
function.
If the vehicle is not equipped with an E-LSD, skip
to step 3.
i
Information
For E-LSD equipped vehicles, shifting into the
transmission into neutral and releasing the
EPB is necessary to turn the propeller shaft to
access the bolts.
3.
Refer to the applicable shop manual to remove
the rear propeller shaft to access the rear
differential lock nut.
Driveshaft and Axle → Propeller Shaft Assembly
→ Propeller Shaft
TSB #: 23-DS-004G-1
Page 7 of 17
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
*Transfer case/transmission and rear differential
flanges
F
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.
G
NOTICE
•
•
•
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 #: 23-DS-004G-1
H
During reassembly, align the dot (G) on
the flange with the stripe (H) on the
propeller shaft rubber coupler.
Page 8 of 17
SUBJECT:
5.
6.
After removal of the propeller shaft, 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
7.
Mark a second line 6.7mm to the left of the first.
2
1
TSB #: 23-DS-004G-1
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SUBJECT:
8.
Tighten the lock nut using a 1/2-inch impact
wrench with a 30mm 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 one to two
seconds. Stop when the nut reaches the 6.7mm
mark or 30° of rotation.
Tightening Range
Minimum: 4.5mm, 20°
Target: 6.7mm, 30°
Maximum: 13.3mm, 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.
If differential replacement is necessary, refer to
the procedures in Rear Differential
Replacement below.
TSB #: 23-DS-004G-1
Alignment of the 2 marks indicates the nut
tightened to the target 30°.
Page 10 of 17
SUBJECT:
9.
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.
TSB #: 23-DS-004G-1
Page 11 of 17
SUBJECT:
10. 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.
1. Flange to transmission/transfer case
2. Center bearing bracket
3. Flange to rear differential
TSB #: 23-DS-004G-1
2
1
3
Front
Page 12 of 17
SUBJECT:
After reassembly, drive the vehicle to inspect for
the rear differential noise.
•
•
JK1: Whine noise while gradually
accelerating in the speed range of 37 to
70mph (approx. 60 to 110 kph)
JX1 and RG3: Whine noise while coasting,
off throttle, in the speed range of 50 to 25mph
(approx. 80 to 40 kph)
i
Information
The noise does not have to occur during the
entire speed range.
If the noise as described above is heard, replace
the differential. Refer to the procedures in Rear
Differential Replacement below.
If other noises are heard, continue to diagnose,
and repair the vehicle as necessary.
If the noise is not heard, the service procedure is
now complete.
TSB #: 23-DS-004G-1
Page 13 of 17
SUBJECT:
Rear Differential Replacement
1.
Follow steps 1 to 4 in the “Rear Differential Lock
Nut Tightening” procedures to remove the
propeller shaft again.
2.
Refer to the applicable shop manual to remove
and install the new rear differential.
Driveshaft and Axle → Differential Carrier
Assembly → Rear Differential Carrier
If the vehicle is equipped with an E-LSD, remove
it before removing the differential.
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.
Upload the photos to STUI.
H
TSB #: 23-DS-004G-1
Page 14 of 17
SUBJECT:
4.
After reinstalling the rear differential carrier, use
a feeler gauge to ensure there is a gap of less
than 0.04mm between the rear differential carrier
cover and the bushing protrusion.
If the gap is larger than 0.04mm, the differential
carrier and the bushing may not be aligned
properly. Loosen the bolts to align the
differential, then torque the bolts to specification.
5.
Fill the differential with gear oil.
Model
JK1
Capacity
Type
1.2 +/- 0.05 L
(1.27 +/- 0.05 qt)
75W-85 LSD*
P/N: 00232-19075
JX1
1.3 +/- 0.05 L
(1.37 +/- 0.05 qt)
RG3
1.2 +/- 0.05 L
75W-85 Non LSD
(1.27 +/- 0.05 qt)
P/N: 00232-19097
*LSD gear oil designates the specification, not if
the vehicle is equipped with an E-LSD.
TSB #: 23-DS-004G-1
Page 15 of 17
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)
N
M
Reusing parts will not provide the correct
clamping force and can cause the exhaust to
leak.
Propeller shaft to
rear differential
O
P
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.
1. Flange to transmission/transfer case
2. Center bearing bracket
3. Flange to rear differential
2
1
3
Front
7.
Perform a suspension alignment on an alignment
rack.
TSB #: 23-DS-004G-1
Page 16 of 17
SUBJECT:
8.
After reassembly, drive the vehicle to inspect for
the rear differential noise.
If noise is not heard, the service procedure is
now complete.
If other noises are heard, continue to diagnose,
and repair the vehicle as necessary.
i
Information
Do not tighten the lock nut on the new
differential if a noise is heard.
TSB #: 23-DS-004G-1
Page 17 of 17
SUBJECT: