Assemble

Differential Housing Assembly Assemble

- Tools Required
- J 44809 Output Shaft Seal Installer
- J 44851 Pinion Seal Installer
- J 44852 Front Clutch Drum Seal Installer
- J 44853 Rear Clutch Drum Seal Installer
- J 44868 Housing Spreader
- J 44873 Shoulder Bolts
- J 46607 Alignment Tool
- SA9114T Converter Bearing Installer






Notice: Do not use excessive amounts of sealer. Excess sealer could plug the vent passage, the oil pump, and/or the oil pump screen causing internal damage.

Important: Sealer cure time is 8 hours prior to a fluid fill.

Important: Ensure sealing surface is still clean and oil free.

1. Apply sealer Saturn P/N 12346240 to the rear housing sealing surface (1). Do not apply sealer to vent walls (2). Apply a constant bead of sealer 2.5 mm (0.098 inch) wide and thick.





2. Install the dial indicator on the cover at the top of the bearing bore. Preload the indicator and zero it out.
3. Install J 44868 on the cover.
4. Spread the cover while measuring the movement. Do not spread the cover more than 0.30-0.40 mm (0.0 12-0.016 inch).
5. After the spread is reached, remove the dial indicator.





6. Install the cover.

Notice: Refer to Fastener Notice in Cautions and Notices.

7. Install the 4 (M8) cover bolts and tighten in a criss-cross pattern.
- Tighten the cover bolts (M8) to 24 Nm (18 ft. lbs.).
8. Remove the housing spreader J 44868.






Important: RTV cure time is 8 hours before an oil fill.

9. Install 4 (M10) cover bolts and tighten in a criss-cross pattern.
- Tighten the cover bolts (M10) to 52 Nm (38 ft. lbs.).





10. Using J 44853 install the clutch drum rear oil seal (1) to the differential housing.





11. Install the bearing (1) and the snap ring (2) to the clutch cover. If removed, the bearing will have to be pressed in. Press the bearing from the outer race. Use SA9114T from SA1991T2 automatic transmission tool kit or equivalent.





12. Using J 44852 install the front clutch drum oil seal.





13. Install the filter assembly.
14. Install the dowel pins.





15. Align the clutch with the pump and the pump bushing. Place J 46607 in the splines of the clutch. Twist J 46607 back and forth to align the pump and the bushing. With a properly aligned clutch, the groove on J 46607 will be flush with the drum as shown. Remove J 46607 by pulling straight out.





16. Install the clutch drum (1) on the pinion shaft (2).
17. It will be necessary to shake and twist the clutch drum back and forth to engage the splines into the pump rotor and bushing.





18. A properly installed clutch drum will be fully engaged into the seal (1).






Important: Sealer cure time is 8 hours prior to the fluid fill.

19. Apply sealant to the sealing surface of the differential housing. Apply a constant bead of sealer 2.5 mm (0.098 inch) wide and thick.





20. Install the clutch cover (1) and bolts (2) to the differential housing and tighten the bolts.
- Tighten the clutch cover bolts to 24 Nm (18 ft. lbs.).





21. Install the dust deflector (2) to the flange (1) it required.





22. Using J 44851 (1), install the seal (2) into the housing (3).





23. Install the flange (2) and a new nut (1) to the pinion shaft.





24. Install J 44873 (1) to the pinion flange (2) using 2 prop shaft bolts. Attach half drive breaker bar in order to hold the pinion flange to tighten the nut.
- Tighten the pinion shaft nut to 203 Nm (150 ft. lbs.).





25. Using J 44809, install the right axle shaft oil seal (1) into the differential housing.





26. Install the rear mounting bracket (2), bolts (3) and the new nuts (1) to the differential housing and tighten the bolt.
- Tighten the bracket-to-rear drive module bolts to 105 Nm (77 ft. lbs.).





27. Apply or equivalent on the threads and install the vent to the differential housing, it removed (1).





28. Apply Saturn P/N 21485278 or equivalent to the drain plug threads.
29. Install the drain plug to the differential housing and tighten.
- Tighten the drain plug to 30 Nm (22 ft. lbs.).
30. Apply sealant Saturn P/N 21485278 or equivalent to the threads of the fill plug.
31. Install 750 mm (25.4 oz) GM VERSATRAK fluid after the axle is installed in the vehicle.





32. Install the fill plug and tighten.
- Tighten the fluid fill plug to 35 Nm (26 ft. lbs.).