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Differential Case Assembly Assemble: Assemble

WARNING: This page is about a different car, the 2008 Saab 9-7X. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations .
    2. Fig 1: Exploded View Of Differential Case
    GM680404Courtesy of GENERAL MOTORS CORP.
  2. Install the differential side gear thrust washers to the differential side gears.
  3. Install the differential side gears and thrust washers into the differential case.

    If the same differential side gears and the thrust washers are being used, install the side gears and the thrust washers to their original locations.

  4. Install the differential pinion gears and thrust washers by performing the following steps:
    1. Position one pinion gear between the differential side gears.
    2. Position the second pinion gear between the differential side gear directly opposite of the first gear.
    3. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case.
    4. Install the thrust washers.

      Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.

  5. Install the pinion gear shaft.
  6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.
    7. Fig 2: Ring Gear & Differential Case
    GM866505Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
  7. Install the ring gear onto the differential case.
    8. IMPORTANT: The ring gear bolts have left-hand threads.
  8. Install the new ring gear bolts.

    Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

    9. NOTE: Refer to Fastener Notice .
  9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

    Tighten:  Tighten the ring gear bolts in sequence to 83 N.m (61 lb ft).

    10. Fig 3: Installing Differential Side Bearing
    GM680453Courtesy of GENERAL MOTORS CORP.
  10. Install the differential side bearings by performing the following steps:
    1. In order to protect the differential case, install the J 8107-2  in the case on the side opposite the bearing installation.
    2. Install the J 33790  (2) and the J 8092  (1) onto the differential case bearing as shown. See Special Tools .
    3. Install the differential case bearings using the J 33790  and the J 8092  . See Special Tools .
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