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When you are working under your vehicle,
make sure it is supported by secure jack stands. There is always
accident reports indicating someone has perished because of working under
a car that was only supported by the jack. Do not take any
chances.....

Changing
the differential fluid is valued at approximately a $135 for the service
and fluids. It really doesn't take that long, nor is it that
difficult. The procedure just seems a bit daunting when you first
think about doing the work on your own. The
subject vehicle for this procedure is a 2002 GT. You will require a
3/8 drive socket set, a slot screw driver, a scraper tool and some high
temperature silicone and a drain pan. The fluid required is 2
quarts/litres of differential fluid and 2 bottles of Friction
Modifier. The differential is a limited slip configuration and the
clutches require the addition of the friction modifier. People who
leave out the friction modifier will start to generate excessive rear end
noise and will have to add it anyway. Start
by putting the car up on a lift or jacking the car up as high as possible
and supporting it with jack stands. Do not, absolutely do not
attempt this procedure with the vehicle supported only by the lifting
jack. 
Once you
have the vehicle securely supported by jack stands, start by loosening all
the bolts that surround the rear differential pan. There will
be a aluminum tag attached to one or more of the bolts that specify the
gear configuration of you vehicle unless you have changed the gear
ratio. If you have these, don't loose them, we will replace them
during re-assembly. Once you have removed all the bolts, slow pry
the pan away from the differential housing near the bottom, being careful
to not damage the pan. You will need just enough prying force to
break the silicone seal between the two mating surfaces. Once you
have broken the seal just enough for the fluid to start running, let it
run. This is nasty smelling stuff and you don't want to get any on
your clothing. 
Once
you have drained the differential completely, continue to pry the pan away
until it is free. Remove it completely by lifting it up over the
rear sway bar. Use the scraper to remove all the excess silicone
sealant from the mating edge of the pan, and clean any fluid gunk from the
pan itself. Re-direct
your attention to the mating surface of the differential housing and clean
it with the scraper as well. There is always some differential fluid
that does not drain out completely. Take some throw away rags or
paper towel and clean the bottom of the housing. Once complete,
clean clean the mating housing surface again with some solvent so that it
is clean and dry.

The
pan will now need to have the high temperature silicone applied to it
before closing up the differential. It is easier to apply this to
the pan than to the vertical surface of the housing. Carefully maneuver
the pan back into position being careful not to touch the silicone surface
to anything. Any contamination could be a source for a leaky rear
end. Replace a the bolts with any tabs and finger tighten as much as
possible. With your socket, slowly tighten each bolt using a criss-cross
pattern. This will ensure a good flat mating surface between the pan
and the housing. If
time permits, it is best to leave the pan for several hours or over night
to allow the silicone to cure completely. This really diminishes the
possibility of leaks. 
When
the minimum time specified has elapsed, a socket driver with an extension
will be required to remove the filler plug on the front side of the
differential. This is on the drivers side, just above half
way. Cut the end off of the spout provided on the differential fluid
and empty 2 quarts/litres into the differential. Now add the 2
bottle of friction modifier and the housing should be full. If it
does not already start running out, you should at least be able to stick
you finger into the hole, and touch the fluid, this is adequate. If
not, you may have to add a portion of another quart/litre of differential
fluid. Replace
the plug and tighten. Over tightening can strip the thread and lead
to a cost repair and a pile of wasted fluid. I had the transmission
in neutral, which allowed me to turn the drive shaft a couple of
revolutions, making sure the gear surfaces where covered and to help mix
the fluid and the friction modifier. Check all you bolts and plugs
are secure, slowly let the car down off the jack stands and you are
finished. |