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Differential Assembly: Installation

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the torque tube to the differential. See TORQUE TUBE ASSEMBLY  . Tighten torque tube-to-differential bolts to specification. See TORQUE SPECIFICATIONS  . Install the rear differential and torque tube assembly to the suspension cradle. Simultaneously guide the left wheel axle shaft onto the differential output shaft while positioning the differential assembly to the suspension cradle. Place an adjustable support under the torque tube. Ensure that the left wheel axle shaft is fully engaged to the differential output shaft. Install the differential carrier mounts, washers, bolts and nuts to the differential. See Figure .
  2. Tighten the differential carrier-to-cradle mounting bolts to specification. See TORQUE SPECIFICATIONS  . Install the torque tube bracket-to-body bolts. Tighten the torque tube bracket-to-body bolts to specification. Tighten the torque tube-to-bracket through-bolt and nut to specification. Install the drive shaft. See DRIVE SHAFT & UNIVERSAL JOINTS in appropriate DRIVELINE/AXLE article. Install the right rear wheel axle shaft. Install the right rear tire and wheel assembly. Install the differential drain plug and gasket to the differential. Tighten the drain plug to specification. See TORQUE SPECIFICATIONS  .
  3. Remove the differential fill plug. Fill the axle with synthetic gear oil. See LUBRICATION  . Inspect the differential oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. Install the differential fill plug and gasket. Tighten to specification. See TORQUE SPECIFICATIONS  .
  4. Connect the electrical connector to the clutch pump check valve. Remove the adjustable support from the torque tube. Lower the vehicle. Operate the vehicle making tight left, then right turns in order to engage the all-wheel-drive system and distribute the gear oil throughout the differential. Raise and support the vehicle. Remove the differential fill plug. Fill the axle with synthetic gear oil. See LUBRICATION  . Inspect the differential oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. Install the differential fill plug and gasket. Tighten the fill plug to specification. Lower the vehicle.
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