Removal & Installation
Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.
- Remove the drain plug and the drain the fluid.
- Remove the fill plug.
Remove the rear mounting bracket (2) and the bolts (3).
- Install J 44873, Pinion Flange Holder and Remover, to the pinion flange using 2 prop shaft bolts.
- Attach half drive breaker bar in order to hold the pinion flange to remove nut.
- Remove the nut and the flange. Discard the used nut.
- Remove the dust deflector from the flange, if required.
- Remove the input flange oil seal from the clutch cover.
- Remove the bolts and the clutch cover from the differential housing.
- Remove the filter assembly.
Remove the dowel pins.
WARNINGDo not submerge the clutch drum in solvent. This will damage the friction material and gerotor pump.
NOTEThe clutch drum is not serviceable. If inoperative conditions are found, replace the unit.
- Remove the clutch drum from the clutch cover.
Remove the snapring (1) from the clutch cover.
- Remove the bearing. Only remove the bearing if it is going to be replaced. It must be pressed out by the inner race.
- Remove the clutch drum rear oil seal from the housing.
- Attach the assembly holding fixture J 44869 to the housing, using 4 clutch cover bolts.
Install the housing (1) and the fixture into J 43964, Engine Stand Fixture Adapter (2) adapter.
Remove the rear cover bolts: 4 M8 and 4 M10.
WARNINGUse the pry point only. Do not pry on the sealing surface.
NOTEThe rear differential carrier may come out with the cover.
Remove the rear cover by prying it off at the pry point locations.
Remove the right and the left axle shaft oil seals.
- Remove the differential carrier. Place a screw driver in the axle differential bore and pry up.
- Mark or tag the bearing races and the shims for assembly.
Remove the carrier assembly (1), bearing races (2), and shims (3).
NOTEThe ring gear bolts are not to be reused. Use new bolts during assembly.
- Remove the bolts and the ring gear from the carrier.
Identify the lock pin location (1) within the differential case.
Drive the pinion shaft roll pin from the access hole (3) until the pinion shaft (2) can be removed from the differential case (1).
- Remove the washers (1), pinion gears (2) and side gears (3) from the differential case.
- Using J 44854, Side Bearing Remover (3), J 22912-01 Bearing Puller (2), and J 44855, Side Bearing Installer (1), place the carrier into a press and press off the bearing.
Turn the carrier over, using the same press, remove the right side differential bearing.
- Using a punch, bend out the flat on both sides of the pinion nut.
Place J 44864, Pinion Nut Wrench (1) over the pinion shaft. Turn the shaft to align the hex nut with the flat on the assembly holding fixture J 44869 (2).
Place J 44865 Spline Socket and the breaker bar over the pinion splines. Remove the nut.
NOTEThe pinion nut is not reusable.
- Remove J 44864, Pinion Nut Wrench and the nut.
Remove the 4 bolts from J 44869, Assembly Holding Fixture, and remove from the housing.
WARNINGInspect the press bar surface. Do not press the housing against a rough surface. Sealing surfaces could be damaged.
Position the differential housing into a press in order to remove the pinion shaft.
NOTEThe collapsible spacer is not reusable.
Remove the front bearing (1), the collapsible spacer (2) and the pinion shaft (3).
WARNINGIf dowel pins are still in the housing, remove them before pressing. Pressing on dowels will damage the housing.
NOTEThe bolt is left-hand threaded on J 3940, Bearing Race Remover.
- Place J 3940, Bearing Race Remover, behind the front bearing race in the grooves. Spread the arms and tighten the lock bolt.
Place the housing in a press and remove the race.
NOTEThe bolt is left-hand threaded on J 3940, Bearing Race Remover.
- Place J 3940, Bearing Race Remover, behind the rear pinion bearing race in the grooves. Spread the arms and tighten the lock bolt.
- Place the housing in a press and remove the race.
Using J 44858 Pinion Bearing Remover (2), and J 22912-01 Bearing Puller (1), place the V of the split plate in the groove of J 44858 Pinion Bearing Remover (2). Tighten the nuts.
NOTEThe pinion shim is located under the bearing. Measure and mark or tag when removed.
- Place the pinion shaft and the tools in a press; then remove the bearing and the shim.
Apply sealer Saturn P/N 21019581 to the rear housing sealing surface (1). Do not apply sealer to vent walls (2). Apply a constant bead of sealer 0.098 in. (2.5mm) wide and thick.
- Install the dial indicator on the cover at the top of the bearing bore. Preload the indicator and zero it out.
- Install J 44868, Housing Spreader, on the cover.
- Spread the cover while measuring the movement. Do not spread the cover more than 0.012-0.016 in. (0.30-0.40mm).
After the spread is reached, remove the dial indicator.
- Install the cover.
- Install the 4 (M8) cover bolts and tighten in a criss-cross pattern. Tighten the cover bolts (M8) to 18 ft. lbs. (24 Nm).
- Remove the housing spreader J 44868 .
- Install 4 (M10) cover bolts and tighten in a criss-cross pattern. Tighten the cover bolts (M10) to 38 ft. lbs. (52 Nm).
- Using J 44853, Rear Clutch Drum Seal Installer, install the clutch drum rear oil seal to the differential housing.
- Install the bearing and the snapring to the clutch cover. If removed, the bearing will have to be pressed in. Press the bearing from the outer race. Use SA9114T, Converter Bearing Installer, from SA1991T2 automatic transaxle tool kit or equivalent.
- Using J 44852 install the front clutch drum oil seal.
- Install the filter assembly.
- Install the dowel pins.
- Align the clutch with the pump and the pump bushing. Place J 46607, Alignment Tool, in the splines of the clutch. Twist J 46607 back and forth to align the pump and the bushing. With a properly aligned clutch, the groove on J 46607 will be flush with the drum. Remove J 46607 by pulling straight out.
Install the clutch drum (1) on the pinion shaft (2) carefully.
- A properly installed clutch drum will be fully engaged into the seal.
Apply sealant Saturn P/N 21019581 to the sealing surface of the differential housing. Apply a constant bead of sealer 0.098 inch (2.5mm) wide and thick.
- Install the clutch cover and bolts to the differential housing and tighten the bolts.
- Tighten the clutch cover bolts to 18 ft. lbs. (24 Nm).
- Install the dust deflector to the flange if required.
- Using J 44851, Pinion Seal Installer, install the seal into the housing.
- Install the flange and a new nut to the pinion shaft.
- Install J 44873, Pinion Flange Holder and Remover (1), to the pinion flange (2) using 2 shoulder bolts. Attach half drive breaker bar in order to hold the pinion flange to tighten the nut.
- Tighten the pinion shaft nut to 150 ft. lbs. (203 Nm).
- Using J 44809, Output Shaft Seal Installer, install the right axle shaft oil seal into the differential housing.
- Install the rear mounting bracket (2), bolts (3) and the new nuts (1) to the differential housing and tighten the bolt.
Tighten the bracket-to-rear drive module bolts to 77 ft. lbs. (105 Nm).
- Apply Saturn P/N 21485278 or equivalent on the threads and install the vent to the differential housing, if removed.
- Apply Saturn P/N 21485278 or equivalent to the drain plug threads.
- Install the drain plug to the differential housing and tighten. Tighten the drain plug to 22 ft. lbs. (30 Nm).
- Apply sealant Saturn P/N 21485278 or equivalent to the threads of the fill plug.
- Install 25.4 oz. (750mm) GM VERSATRAK®fluid Saturn P/N 12378514 after the axle is installed in the vehicle.
- Install the fill plug and tighten. Tighten the fluid fill plug to 26 ft. lbs. (35 Nm).