Rear Axle - Assemble

Tool Required

• J 8001  Dial Indicator Set. See Special Tools and Equipment .
• J 46405  Output Shaft Seal Installer. See Special Tools and Equipment .
• J 42155  Differential Lifting Tool. See Special Tools and Equipment .
• J 42157  Left Output Shaft Bearing Installer. See Special Tools and Equipment .
• J 42164  Pinion Gear Holder. See Special Tools and Equipment .
• J 42170  Bearing and Race Installer. See Special Tools and Equipment .
• J 42173  Differential Holding Fixture. See Special Tools and Equipment .

Fig 1: Left Side Cover Output Shaft Bearing
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If the pinion assembly components have not been replaced, reuse the original pinion housing shims. If the pinion assembly components have been replaced, refer to Drive Pinion Shim Selection  for selection of the proper size shims.
1. Assemble the drive pinion prior to rear axle assembly. Refer to Drive Pinion Assemble .
2. Install the bearing (1) to the cover - left.
Fig 2: Bearing, Left Cover & J 42157
Courtesy of GENERAL MOTORS CORP.
3. Install the bearing into the cover - left using the J 42157  and a hydraulic press. See Special Tools and Equipment .
Fig 3: Oil Seal, Left Cover & J 46405
Courtesy of GENERAL MOTORS CORP.
4. Install the oil seal into the cover - left using the J 46405  . See Special Tools and Equipment .
Fig 4: Oil Seal, Right Cover & J46405
Courtesy of GENERAL MOTORS CORP.
5. Install the oil seal into the cover - right using the J 46405  . See Special Tools and Equipment .
Fig 5: Pinion Housing/Cage Assembly, Shims & Differential Housing
Courtesy of GENERAL MOTORS CORP.
6. Install the pinion housing assembly (2) and the selected shim or shims (1) to the differential housing. Refer to Drive Pinion Shim Selection  for shim selection.

   The use of M8 x 1.25 dowels or long bolts will ease in pinion housing/cage and shim installation and alignment.

Fig 6: Pinion Housing/Cage Bolts
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice in Cautions and Notices.
7. Install the pinion housing/cage bolts (1).

   Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

Fig 7: Output Shaft & C-Clip
Courtesy of GENERAL MOTORS CORP.
8. Install the C-clip (1) into the groove of the output shaft.
Fig 8: Differential, Transmission Stud Bolts & Mount
Courtesy of GENERAL MOTORS CORP.
9. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the threads of the bolts (2) and stud (1). Apply sealant only to the end of the stud that installs into the mount.
10. Install the mount (3) and bolts (2).

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

11. Install 2 M10 x 1.5 nuts onto the transmission stud (1). Install the stud into the mount.

    Tighten:  Tighten the stud to 42 N.m (31 lb ft).

Fig 9: Differential Cover (Right), Axle Seal & O-Ring Seal
Courtesy of GENERAL MOTORS CORP.
12. Install the O-ring (4) to the groove of the cover - right (3).
13. Install the cover - right and bolts (2).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

Fig 10: Transmission Stud & Ring Gear Tooth Surface
Courtesy of GENERAL MOTORS CORP.
14. Install the J 8001  onto the transmission stud. See Special Tools and Equipment . Position the tip of the dial indicator against the center of the ring gear tooth surface.
Fig 11: Splines Of Pinion & J 42164
Courtesy of GENERAL MOTORS CORP.
15. Install the J 42164  (1) into the splines of the pinion J 42164  will retain the pinion in order to properly measure backlash. See Special Tools and Equipment .
Fig 12: Moving Right Output Shaft In Both Directions
Courtesy of GENERAL MOTORS CORP.
16. Move the output shaft - right in both directions in order to measure the gear backlash. Measure the backlash in two to three locations. Refer to Rear Axle Specifications .
Fig 13: Cover-Rear, Bolts, Bolt/Stud & O-Ring
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Note the location of the cover - rear bolt/stud for assembly.
17. Install the cover - rear (2), bolts (3), bolt/stud (4), and O-ring (1).

    Tighten:  Tighten the bolts and bolt/stud to 10 N.m (89 lb in).

Fig 14: J 42173 & Differential Assembly
Courtesy of GENERAL MOTORS CORP.
18. Remove the bolts (3) and the differential assembly (1) from the J 42173  (2). See Special Tools and Equipment .
Fig 15: Differential Cover (Left), O-Ring Seal & Bolts
Courtesy of GENERAL MOTORS CORP.
19. Install the O-ring (4) into the groove of the cover - left (3).
20. Install the magnet (5) to the carrier.
21. Apply a continuous 3 mm (0.125 in) bead of sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the left cover flange (3).
22. Apply sealant around the bolt holes. Keep the sealant away from the O-ring.
23. Install the cover - left (3) and bolts (2).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

24. Clean the excess sealant from the left cover/housing splitline.
Fig 16: Vehicle Speed Sensor & Bolt
Courtesy of GENERAL MOTORS CORP.
25. Install the vehicle speed sensor and bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

Fig 17: Differential, Drain Plug & Washer
Courtesy of GENERAL MOTORS CORP.
26. Install the drain plug (1) and washer (2).

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

Fig 18: Fill Plug, Lubricant Tag & Washer
Courtesy of GENERAL MOTORS CORP.
27. Install the fill plug (3), lubricant tag (2), and washer (1).
Fig 19: View Of Transaxle Mount Bracket & Bolts
Courtesy of GENERAL MOTORS CORP.
28. Install the transmission mount and bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).