Differential Case Assemble

Tools Required

• KM-525  Installer
• KM-522  Installer
• KM-520  Remover/Installer. See Special Tools .

Fig 1: Speedometer Drive Gear, Differential Gear Housing & KM-525
Courtesy of GENERAL MOTORS CORP.
1. Install the speedometer drive gear onto the differential gear housing using the KM-525  (1).
Fig 2: Differential Bearings & KM-525
Courtesy of GENERAL MOTORS CORP.
2. Install both of the differential bearings using the KM-522  (1).
Fig 3: Pinion Gear, Washers & Side Gears
Courtesy of GENERAL MOTORS CORP.
3. Install the side gears and the side thrust washers into the differential housing.
4. Install the differential pinion gears and the differential pinion gear washers into the differential housing.
Fig 4: Pinion Gear Shaft
Courtesy of GENERAL MOTORS CORP.
5. Install the pinion gear shaft into the differential housing.
Fig 5: Pinion Gear Shaft, Lock Pin & Differential Housing
Courtesy of GENERAL MOTORS CORP.
6. Install the pinion gear shaft lock pin into the differential housing and the pinion gear shaft.
Fig 6: Ring Gear & Bolts
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice .
7. Install the ring gear and the ring-gear bolts.

   Tighten:  Tighten the ring-gear bolts to 70 N.m (52 lb ft).

Fig 7: Differential Assembly & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
8. Install the differential assembly into the transaxle case.
Fig 8: Right-Side Bearing-Retainer & Bolts
Courtesy of GENERAL MOTORS CORP.
9. Install the right-side bearing retainer and the right side bearing retainer and the right side bearing retainer bolts.

   Tighten:  Tighten the right-side bearing retainer bolts to 25 N.m (18 lb ft).

Fig 9: Bearing-Adjusting Ring & KM-520
Courtesy of GENERAL MOTORS CORP.
10. Install the bearing-adjusting ring.
11. Tighten the bearing-adjusting ring using the KM-520  (1). See Special Tools .

    Tighten:  Tighten the bearing adjusting ring until there is no end play with the differential.

12. Adjust the preload on the differential bearings.

    Specification: 

    • Used Bearings: 1 N.m (9 lb in) is required to rotate the differential one revolution per second.
    • New Bearings: 2 N.m (18 lb in) is required to rotate the differential one revolution per second.

    Tighten or loosen the bearing ring adjuster to get the required preload on the bearings.

Fig 10: Bearing-Adjusting Ring, Retainer Plate & Bolt
Courtesy of GENERAL MOTORS CORP.
13. Install the bearing-adjusting ring-retainer plate and the bearing-adjusting ring-retainer plate bolt.

    Tighten:  Tighten the bearing-adjusting ring-retainer plate bolt to 5 N.m (44 lb in).

Fig 11: Differential Cover & Bolts
Courtesy of GENERAL MOTORS CORP.
14. Install the differential cover gasket, the differential cover, and the differential cover bolts.

    Tighten:  Tighten the differential cover bolts to 40 N.m (30 lb ft).