Differential Carrier Assembly Replacement

Differential Carrier Assembly Replacement

Removal Procedure

Note: The following service procedure is also to include those vehicles with RPO G96.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. If replacing the rear differential assembly, drain the rear differential fluid.

* For those vehicles equipped with the G96 option, refer to Differential Clutch Oil Replacement (Differential Clutch Oil Replacement).
* For those vehicles without the G96 option, refer to Differential Oil Replacement (Removal and Replacement).

3. Remove the propeller shaft assembly. Refer to Propeller Shaft Diagnosis (Testing and Inspection).
4. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (GNC) (Stabilizer Shaft Replacement (GNC))Stabilizer Shaft Replacement (GNE) (Stabilizer Shaft Replacement (GNE)).
5. Remove the wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement (Service and Repair).
6. Disconnect the electrical connectors from the rear differential assembly to the chassis.

Note: Ensure that the rear differential is securely fastened to the hydraulic jack stand.

7. Support the rear differential assembly with a hydraulic transmission jack.




8. Remove the rear differential assembly mounting bolts (1).




9. Remove the front differential mounting bolts (1).




10. Using the hydraulic jack stand, remove the rear differential assembly (1) from the vehicle.
11. Remove the differential clutch assembly, if needed. Refer to Differential Clutch Replacement (Differential Clutch Replacement)

Installation Procedure

1. Install the differential clutch assembly, if removed. Refer to Differential Clutch Replacement (Differential Clutch Replacement)




2. Using the hydraulic jack stand, position the rear differential assembly (1) in the vehicle.




3. Clean the bolts and apply thread locker on the threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers)

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the front differential mounting bolts (1) and tighten to 125Nm (92 lb ft).




5. Install the rear differential assembly mounting bolts (1) and tighten to 90 Nm (66 lb ft) + 100 degrees .
6. Remove the hydraulic jack stand.
7. Install the wheel drive shafts. Refer to Rear Wheel Drive Shaft Replacement (Service and Repair).
8. Install the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (GNC) (Stabilizer Shaft Replacement (GNC))Stabilizer Shaft Replacement (GNE) (Stabilizer Shaft Replacement (GNE)).
9. Reconnect the electrical connectors from the rear differential assembly to the chassis.
10. Install the propeller shaft assembly. Refer to Propeller Shaft Diagnosis (Testing and Inspection).
11. Check the fluid level of the rear differential assembly.

* For those vehicles equipped with the G96 option, refer to Differential Clutch Oil Inspection (Differential Clutch Oil Inspection).
* For those vehicles without the G96 option, refer to Rear Axle Lubricant Level Inspection (Procedures).

12. If installing a NEW rear differential assembly, fill with the proper fluid.

* For those vehicles equipped with the G96 option, refer to Differential Clutch Oil Replacement (Differential Clutch Oil Replacement).
* For those vehicles without the G96 option, refer to Differential Oil Replacement (Removal and Replacement).

13. Remove the supports and lower the vehicle.