Disassembly Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.

Place a pan under the differential assembly.
Remove the fill plug and drain plug from differential carrier.
Remove the differential from the vehicle. Refer to DIFFERENTIAL CARRIER ASSEMBLY REPLACEMENT .
Remove the 4 coupling cover bolts.
Remove the coupling cover from the differential assembly.
Remove the washer and spacer from the differential assembly.
Install the J 8001 against the a ring gear tooth.
Hold the pinion gear stationary.
Move the ring gear back and forth as far as it will travel without turning the pinion gear.

Fig 1: Checking Differential Backlash
Courtesy of GENERAL MOTORS CORP.

Important: Check the differential backlash at 3 different positions on the ring gear to obtain an accurate reading.
Observe the J 8001 while moving the ring gear as previously described. Differential backlash should be within 0.10 mm - 0.15 mm (0.0039 - 0.0059 in).
Using a torque wrench (1) and J 46004 , measure and record the drive pinion starting preload. Preload should be between 0.4 - 0.7 N.m (3.0 - 6.0 in lb).

Fig 2: Measuring Drive Pinion Starting Preload
Courtesy of GENERAL MOTORS CORP.
Remove the differential carrier side oil seals using the J 29369-2 and the J 23907.

Fig 3: Removing Differential Carrier Side Oil Seals
Courtesy of GENERAL MOTORS CORP.
Using a hammer and punch, unstake the drive pinion nut.

Fig 4: Unstaking Drive Pinion Nut
Courtesy of GENERAL MOTORS CORP.
Using J 46004 and J 46002 , remove the pinion nut.
Remove the differential carrier front oil seal using the J 22888-20A.
Remove the front bearing from the drive pinion.
Remove the vent hose from the differential carrier.

Fig 5: Removing Vent Hose From Differential Carrier
Courtesy of GENERAL MOTORS CORP.
Place reference marks (1) on the elbows and differential carrier.
Remove the 2 elbows using a screwdriver.

Fig 6: Placing Reference Marks On Elbows And Differential Carrier
Courtesy of GENERAL MOTORS CORP.
Remove the 10 differential cover bolts.
Using a brass drift and a hammer, remove the differential cover from the differential carrier.

Fig 7: Removing Differential Cover From Differential Carrier
Courtesy of GENERAL MOTORS CORP.
Remove the differential case from the differential carrier.
Remove the drive pinion and sleeve from the differential carrier.
Remove the drive pinion rear bearing from drive pinion using J 22912-O1 and a press.

Fig 8: Removing Drive Pinion Rear Bearing From Drive Pinion
Courtesy of GENERAL MOTORS CORP.
Remove the differential case side bearings from the differential case using J 22912-O1 and a press.

Fig 9: Removing Differential Case Side Bearings From Differential Case
Courtesy of GENERAL MOTORS CORP.
Place a reference mark (1) on the ring gear and differential case.
Remove the 10 ring gear retaining bolts.
Using a soft faced hammer, tap the ring gear to remove it from the differential case.

Fig 10: Placing Reference Mark On Ring Gear And Differential Case
Courtesy of GENERAL MOTORS CORP.
Use a punch and a hammer in order to remove the pinion shaft roll pin from the differential case.

Fig 11: Removing Pinion Shaft Roll Pin From Differential Case
Courtesy of GENERAL MOTORS CORP.
Remove the following components from the differential case:
- The pinion shaft
- The pinion gears
- The pinion washers
- The differential side gears
- The side gear thrust washers
Clean all the components thoroughly with clean solvent. Dry the components.
Inspect all of the gears for the following conditions. Replace as necessary:
- Cracks
- Chipped teeth
- Broken teeth
- Other damage
Inspect the differential side bearing surfaces. Replace as necessary:
- Roughness
- Excessive wear
Inspect the differential case gear and bearing surfaces for cracks and blue discoloration. These conditions indicate overheating or other damage. Replace as necessary.