Differential Assembly Assemble

Tools Required

• DT 46462  (DW240-140) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools .
• DT 46465  (DW240-170) Adapter Handle. See Special Tools .
• DT 46461  (DW240-130) Differential Preload Adapter. See Special Tools .
• DT 46471  (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools .
• DT 47521  (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools .

Fig 1: Installing Side Bearing Outer Race & Transaxle Housing Using DT 46462 & DT 46465
Courtesy of GENERAL MOTORS CORP.
1. Using the DT 46462  (2) and the DT 46465  (1), install a new side bearing outer race into the transaxle housing. See Special Tools .
Fig 2: Counter Driven Gear Outer Tapered Roller Bearing Race & Shim
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Install a shim of the same thickness as the one removed.
2. Install the shim to the transaxle case.
3. Install a new side bearing outer race into the transaxle case.
Fig 3: Differential Side Gear Thrust Washers & Differential Side Gears
Courtesy of GENERAL MOTORS CORP.
4. Coat the thrust washers, side gears, pinion gears, and pinion thrust washers with automatic transmission fluid (ATF).
5. Install the 2 differential side gear thrust washers to 2 differential side gears.
Fig 4: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
6. Install the 2 side gears with 2 thrust washers, 2 pinion gears, and 2 pinion thrust washers into the differential case.
7. Coat the pinion shaft with ATF.
Fig 5: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
8. Install the pinion shaft so as to align the lock pin holes on the pinion shaft and differential case.
Fig 6: Measuring Side Gear Backlash While Holding 1 Pinion Gear Toward The Case
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If the backlash is out of specification, install the correct thrust washer to the side gear.
9. Measure the side gear backlash while holding 1 pinion gear toward the case.

   Specifications:  The standard backlash is 0.05-0.2 mm (0.002-0.0079 in).

IMPORTANT:
• Try to select washers of the same size for both sides.
• If the backlash is not within the specification, install a thrust washer of a different thickness.
10. Select thrust washers which will ensure that the backlash is within the specification. Refer to Transmission General Specifications .
Fig 7: Driving Pin From Ring Gear Side Using A Pin Punch & Hammer
Courtesy of GENERAL MOTORS CORP.
11. Using a hammer and punch, drive in the pin through the case and holes in the pinion shaft.
Fig 8: Staking The Differential Case Using A Hammer & Chisel
Courtesy of GENERAL MOTORS CORP.
12. Using a hammer and chisel, stake the differential case.
Fig 9: Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
13. Using a press, install the tapered roller bearing into the differential case.
Fig 10: FIPG, Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
14. Using a press, install the tapered roller bearing into the differential case.
15. Remove any formed in place gasket (FIPG) material. Do not get oil on the contacting surfaces of the transaxle housing or transaxle case.
Fig 11: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
16. Install the differential to the transaxle case.
Fig 12: Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
17. Install the transaxle housing and 16 bolts of the transaxle housing temporarily.
NOTE: Refer to Fastener Notice in Cautions and Notices.
18. Tighten 8 or 9 bolts out of the 16 bolts of the transaxle housing completely.

    Tighten:  Tighten the bolts to 29 N.m (22 lb ft).

Fig 13: Turning The Differential Gear Assembly
Courtesy of GENERAL MOTORS CORP.
19. Using the DT 46461  , turn the differential gear assembly right and left 2-3 times to allow the bearing to settle. See Special Tools .
Fig 14: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: If the preload is not within specifications, remove the differential from the transaxle case.
20. Using the DT 46461  and a small torque wrench, measure the preload of the differential gear. See Special Tools .

    Specifications: 

    • New bearing preload is 0.78-1.37 N.m (6.9-12.2 lb in).
    • Used bearing preload is 0.39-0.69 N.m (3.5-6.1 lb in).

21. Re-select the transaxle case side adjusting the shim according to the shim thickness table. Refer to Transmission General Specifications .
Fig 15: Transaxle Housing
Courtesy of GENERAL MOTORS CORP.
22. Using a plastic hammer, remove the 16 bolts and transaxle housing.
Fig 16: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
23. Remove the differential gear from the transaxle case.
Fig 17: Ring Gear & Differential Case
Courtesy of GENERAL MOTORS CORP.
24. Clean the contact surface of the differential case.
25. Heat the ring gear in water and boil for 10 minutes.
26. Carefully remove the ring gear from the water.
27. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
Fig 18: Differential Assembly & Bolts
Courtesy of GENERAL MOTORS CORP.
28. Install the 8 bolts.

    Tighten:  Tighten the bolts to 102 N.m (75 lb ft).

Fig 19: Driving In A Transaxle Housing Oil Seal Using A Hammer & DT 46471
Courtesy of GENERAL MOTORS CORP.
29. Using the DT 46471  (1) and a hammer, drive in a new transaxle housing oil seal. See Special Tools .

    Specifications:  The oil seal in depth is 3.1 mm (0.122 in).

Fig 20: Driving In A Transaxle Case Oil Seal Using A Hammer & DT 46471
Courtesy of GENERAL MOTORS CORP.
30. Using the DT 47521  (1), drive in a new transaxle case oil seal. See Special Tools .

    Specifications:  The oil seal in depth is 4.3 mm (0.169 in).