9. Differential Overhaul
Removal Procedure^ Tools Required
^ J 22888-20 Universal Puller
^ J 22888-30 Puller Legs
^ J 34851 Differential Side Bearing Puller Plug
1. Use a J 22888-20 with two J 22888-30 and a J 34851 for support in order to remove the right differential side bearing from the differential carrier.
2. Remove the speedometer drive gear from the differential carrier.
3. Use the J 22888-20 with the J 22888-30 and the J 34851 for support in order to remove the left differential side bearing from the differential carrier.
4. Remove the eight ring gear bolts and the ring gear from the differential carrier.
5. Use a standard drift punch and a hammer in order to remove the pinion shaft roll pin from the differential carrier.
6. Remove the following components from the differential carrier:
6.1. The pinion shaft
6.2. The pinion gears
6.3. The pinion washers
6.4. The differential side gears
6.5. The side gear selective shims
7. Clean all the components thoroughly with clean solvent. Dry the components.
8. Inspect all of the gears for the following conditions. Replace as necessary:
^ Cracks
^ Chipped teeth
^ Broken teeth
^ Other damage
9. Inspect the differential side bearing surfaces. Replace as necessary:
^ Roughness
^ Excessive wear
10. Inspect the differential case gear and bearing surfaces for cracks and blue discoloration. These conditions indicate overheating or other damage. Replace as necessary.
Installation Procedure
^ J 34851 Differential Side Bearing Puller Plug
^ J 29036 Differential Side Bearing Installer
^ J 8092 Driver Handle
^ J 8001 Dial Indicator Set
1. Install the following components into the differential carrier:
1.1. The side gear selective shims
1.2. The differential side gears
1.3. The pinion gear washers
1.4. The pinion gears
1.5. The pinion shaft
2. Use a J 8001 in order to measure the left differential side gear end play.
2.1. Place the J 8001 plunger between the teeth of the left side gear.
2.2. Use two screwdrivers in order to move the left side gear up and down while observing the J 8001.
2.3. The standard left differential side gear end play should be between 0.05 to 0.33 mm (0.002 to 0.013 inch).
2.4. If the left differential side gear end play is below 0.05 mm (0.002 inch), replace the left side gear selective shim with the appropriate selective shim in order to obtain the proper left differential side gear end play. Refer to Specifications in Manual Transmission/Transaxle.
3. Use a J 8001 in order to measure the right differential side gear end play.
3.1. Place the J 8001 plunger on the rear of the right differential side gear.
3.2. Use the fingertips of both hands in order to gently move the right differential side gear up and down while observing the J 8001.
3.3. The standard right differential side gear end play should be between 0.05 to 0.33 mm (0.002 to 0.013 inch).
3.4. If the right differential side gear end play is below 0.05 mm (0.002 inch), replace the right side gear selective shims to obtain proper right differential side gear end play. Refer to Specifications in Manual Transmission/Transaxle.
4. Use a standard drift punch and hammer in order to install the pinion shaft roll pin into the differential carrier and the pinion shaft. The roll pin should be flush with the differential carrier.
5. Apply Loctite(r) 414 GM P/N 12345493 or equivalent to the threaded portion of all the eight ring gear bolts.
6. Install the ring gear onto the differential carrier. Secure the ring gear With the eight differential ring gear bolts.
^ Tighten the differential ring gear bolts to 85 Nm (63 ft. lbs.).
Notice: Refer to Fastener Notice in Service Precautions.
7. Use a J 29036, a J 8092, and a J 34851 for support in order to install the left differential side bearing onto the differential carrier.
8. Install the speedometer drive gear onto the differential carrier.
9. Use the J 29036 with the J 8092 and the J 34851 for support in order to install the right differential side bearing onto the differential carrier.