Differential Housing Assembly Assemble

Tools Required

• J 44809  Output Shaft Seal Installer. See Special Tools .
• J 44851  Pinion Seal Installer. See Special Tools .
• J 44852  Front Clutch Drum Seal Installer. See Special Tools .
• J 44853  Rear Clutch Drum Seal Installer. See Special Tools .
• J 44868  Housing Spreader. See Special Tools .
• J 44873  Pinion Flange Holder and Remover. See Special Tools .
• J 46607  Alignment Tool. See Special Tools .
• SA9114T  Converter Bearing Installer. See Special Tools .

Fig 1: Differential Housing Assembly
Courtesy of GENERAL MOTORS CORP.
NOTE: Do not use excessive amounts of sealer. Excess sealer could plug the vent passage, the oil pump, and/or the oil pump screen causing internal damage.
IMPORTANT: Ensure sealing surface is still clean and oil free.
1. 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 2.5 mm (0.098 in) wide and thick.
Fig 2: Installing Dial Indicator On Cover
Courtesy of GENERAL MOTORS CORP.
2. Install the dial indicator on the cover at the top of the bearing bore. Preload the indicator and zero it out.
3. Install J 44868  on the cover. See Special Tools .
4. Spread the cover while measuring the movement. Do not spread the cover more than 0.30-0.40 mm (0.012-0.016 in).
5. After the spread is reached, remove the dial indicator.
Fig 3: 4 (M8) Cover Bolts
Courtesy of GENERAL MOTORS CORP.
6. Install the cover.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
7. Install the 4 (M8) cover bolts and tighten in a criss-cross pattern.

   Tighten:  Tighten the cover bolts (M8) to 24 N.m (18 lb ft).

8. Remove the housing spreader J 44868  . See Special Tools .
Fig 4: 4 (M10) Cover Bolts
Courtesy of GENERAL MOTORS CORP.
9. Install 4 (M10) cover bolts and tighten in a criss-cross pattern.

   Tighten:  Tighten the cover bolts (M10) to 52 N.m (38 lb ft).

Fig 5: Installing Clutch Drum Rear Oil Seal Using J44853
Courtesy of GENERAL MOTORS CORP.
10. Using J 44853  install the clutch drum rear oil seal (1) to the differential housing. See Special Tools .
Fig 6: Installing Bearing & Snap Ring On Clutch Cover
Courtesy of GENERAL MOTORS CORP.
11. Install the bearing (1) and the snap ring (2) to the clutch cover. If removed, the bearing will have to be pressed in. Press the bearing from the outer race. Use SA9114T  from SA1991T2 automatic transmission tool kit or equivalent. See Special Tools .
Fig 7: Front Clutch Drum Oil Seal
Courtesy of GENERAL MOTORS CORP.
12. Using J 44852  install the front clutch drum oil seal. See Special Tools .
Fig 8: Filter Assembly
Courtesy of GENERAL MOTORS CORP.
13. Install the filter assembly.
14. Install the dowel pins.
Fig 9: Aligning Clutch With Pump & Pump Bushing
Courtesy of GENERAL MOTORS CORP.
15. Align the clutch with the pump and the pump bushing. Place J 46607  in the splines of the clutch. See Special Tools . Twist J 46607  back and forth to align the pump and the bushing. See Special Tools . With a properly aligned clutch, the groove on J 46607  will be flush with the drum as shown. See Special Tools . Remove J 46607  by pulling straight out. See Special Tools .
Fig 10: Installing Clutch Drum On Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
16. Install the clutch drum (1) on the pinion shaft (2) carefully.
Fig 11: Clutch Drum Oil Seal
Courtesy of GENERAL MOTORS CORP.
17. A properly installed clutch drum will be fully engaged into the seal (1).
Fig 12: RDM Housing Sealing Surface
Courtesy of GENERAL MOTORS CORP.
18. Apply sealant Saturn P/N 21019581 to the sealing surface of the differential housing. Apply a constant bead of sealer 2.5 mm (0.098 in) wide and thick.
Fig 13: Installing Clutch Housing Cover On RDM
Courtesy of GENERAL MOTORS CORP.
19. Install the clutch cover (1) and bolts (2) to the differential housing and tighten the bolts.

    Tighten:  Tighten the clutch cover bolts to 24 N.m (18 lb ft).

Fig 14: Inspecting Dust Deflector For Cracks
Courtesy of GENERAL MOTORS CORP.
20. Install the dust deflector (2) to the flange (1) if required.
Fig 15: Installing Input Shaft Seal On Housing Cover
Courtesy of GENERAL MOTORS CORP.
21. Using J 44851  (1), install the seal (2) into the housing (3). See Special Tools .
Fig 16: Installing Input Flange On Clutch Shaft
Courtesy of GENERAL MOTORS CORP.
22. Install the flange (2) and a new nut (1) to the pinion shaft.
Fig 17: Installing J44873 On Pinion Flange
Courtesy of GENERAL MOTORS CORP.
23. Install J 44873  (1) to the pinion flange (2) using J 44873-2 shoulder bolts. See Special Tools . Attach half drive breaker bar in order to hold the pinion flange to tighten the nut.

    Tighten:  Tighten the pinion shaft nut to 203 N.m (150 lb ft).

Fig 18: Right Rear Wheel & Tire Assembly
Courtesy of GENERAL MOTORS CORP.
24. Using J 44809  , install the right axle shaft oil seal (1) into the differential housing. See Special Tools .
Fig 19: Rear Mounting Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
25. Install the rear mounting bracket (2), bolts (3) and the new nuts (1) to the differential housing and tighten the bolt.

    Tighten:  Tighten the bracket-to-rear drive module bolts to 105 N.m (77 lb ft).

Fig 20: Installing Vent On Differential Housing
Courtesy of GENERAL MOTORS CORP.
26. Apply Saturn P/N 21485278 or equivalent on the threads and install the vent to the differential housing, if removed (1).
Fig 21: RDM Drain Plug
Courtesy of GENERAL MOTORS CORP.
27. Apply Saturn P/N 21485278 or equivalent to the drain plug threads.
28. Install the drain plug to the differential housing and tighten.

    Tighten:  Tighten the drain plug to 30 N.m (22 lb ft).

29. Apply sealant Saturn P/N 21485278 or equivalent to the threads of the fill plug.
30. Install 750 mm (25.4 oz) GM VERSATRAK fluid Saturn P/N 12378514 after the axle is installed in the vehicle. Refer to Lubricant Replacement - Rear Drive Axle .
Fig 22: Fill Plug
Courtesy of GENERAL MOTORS CORP.
31. Install the fill plug and tighten.

    Tighten:  Tighten the fluid fill plug to 35 N.m (26 lb ft).