Differential Bearing Replacement (G86)

Single Use Fasteners and Components Differential Carrier Front Bolt Rear Axle Shaft Seal [2x] Special Tools DT-22888-20A Universal Two Jaw Puller DT-24384-A Oil Seal Installer DT-3289-20 Holding Fixture DT-36597 Side Bearing Puller Pilot - 9.25 Inch DT-52896 Pinion Seal and Side Bearing Installer DT-52900 Rear Cover Spreader Assembly DT-52902 Rear Drive Module Rotating Fixture DT-52903 Axle Flange Remover DT-5590 Bearing and Seal Driver GE-02619-A Slide Hammer w/Adapter Equivalent regional tools: Special Tools Removal Procedure

1. Remove the spare tire.
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Differential Bearing Replacement (G86) — figure 1

3.  Position a drain pan under the rear differential carrier (1).
4. Rear Axle Housing Drain Plug (2) » Remove
5.  Clean the rear axle housing drain plug. Allow the fluid to completely drain.

Caution

Refer to Component Fastener Tightening Caution.

6. Rear Axle Housing Drain Plug (2) » Install and tighten — Fastener Specifications

Differential Bearing Replacement (G86) — figure 2

7. Rear Propeller Shaft Bolt (1) » Remove [4x]

Differential Bearing Replacement (G86) — figure 3

8. Propeller Shaft (1) » Remove

Differential Bearing Replacement (G86) — figure 4

9. Rear Wheel Drive Shaft Bolt (1) » Remove [8x]
10. Reposition the right rear wheel drive shaft downward.

Differential Bearing Replacement (G86) — figure 5

11. Rear Wheel Drive Shaft Bolt (1) » Remove [8x]
12. Reposition the left rear wheel drive shaft downward.

Differential Bearing Replacement (G86) — figure 6

13. {If equipped} with dual exhaust. 13.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 13.2. Spare Wheel Heat Shield (1) » Remove

Differential Bearing Replacement (G86) — figure 7

14. {If equipped} with single exhaust. 14.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 14.2. Spare Wheel Heat Shield (1) » Remove

Differential Bearing Replacement (G86) — figure 8

15. Rear Axle Vent Hose (2) » Disconnect
16. Support the rear differential carrier.

Differential Bearing Replacement (G86) — figure 9

17. Differential Carrier Nut (2) » Remove
18. Differential Carrier Front Bolt (1) » Remove and DISCARD

Differential Bearing Replacement (G86) — figure 10

19. Differential Carrier Rear Bolt (1) » Remove [2x]
20. Lower the rear differential carrier.

Differential Bearing Replacement (G86) — figure 11

21. Install the DT-52902 Rear Drive Module Rotating Fixture (2) to the rear axle housing and attach to the DT-3289-20 Holding Fixture (1).

Differential Bearing Replacement (G86) — figure 12

22. Using DT-52903 Axle Flange Remover (2) and GE-02619-A Slide Hammer w/Adapter (1), Remove the rear axle shaft (3).

Differential Bearing Replacement (G86) — figure 13

23. Rear Axle Shaft Seal (1) » Remove and DISCARD

Differential Bearing Replacement (G86) — figure 14

24. Using DT-52903 Axle Flange Remover (2) and GE-02619-A Slide Hammer w/Adapter (3), Remove the rear axle shaft (1).

Differential Bearing Replacement (G86) — figure 15

25. Rear Axle Shaft Seal (1) » Remove and DISCARD

Differential Bearing Replacement (G86) — figure 16

26. Rear Axle Housing Cover Bolt (1) » Remove [8x]
27. Rear Axle Housing Cover Bolt (2) » Remove [4x]

Differential Bearing Replacement (G86) — figure 17

28. Using the DT-52900 Rear Cover Spreader Assembly (2), Remove the rear axle housing (1).

Differential Bearing Replacement (G86) — figure 18

29. Remove the differential (3), spacers (2), and shims (1).

Differential Bearing Replacement (G86) — figure 19

30. Using DT-22888-20A Universal Two Jaw Puller (1) and DT-36597 Side Bearing Puller Pilot - 9.25 Inch (2), Remove the 2 differential bearings (3). Cleaning and Inspection Procedure - Required
31. Clean any debris and material from the axle housing.
32. Inspect the axle housing for damage and burrs, if any damage or burrs are found replacement of the axle housing would be necessary.
33. Clean off the old sealant from the rear axle housing and rear axle housing cover using Acetone, followed by Isopropyl Alcohol. Installation Procedure

Differential Bearing Replacement (G86) — figure 20

1. Using DT-52896 Pinion Seal and Side Bearing Installer (1) and a shop press, Install 2 differential bearing (2).

2. Measure the thickness needed for the differential bearing shims, refer to Differential Carrier Bearing Preload Adjustment.

3. Measure and adjust the backlash, refer to Backlash Adjustment.

4. Place the spacers (2) and shims (1) on the ends of the differential (3) and set the differential assembly into the rear axle housing.

Note

A dead blow hammer can be used to help seat the differential and shim.

5. Install the differential (3), spacers (2), and shims (1).

Differential Bearing Replacement (G86) — figure 21

Note

Install and align the rear axle housing within 10 minutes of applying sealer.

6. Apply a 4 mm (0.157 in) wide bead of sealant to the rear axle housing per the template above. Adhesives, Fluids, Lubricants, and Sealers The bead should be 2 mm (0.079 in) high and 2 mm (0.079 in) from the chamfer.

7. Using the DT-52900 Rear Cover Spreader Assembly (2), Install the rear axle housing (1).

8. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 8.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 8.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 8.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 8.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution

Refer to Fastener Caution.

9. Rear Axle Housing Cover Bolt (2) » Install and tighten [4x] — Fastener Specifications
10. Rear Axle Housing Cover Bolt (1) » Install and tighten [8x] — Fastener Specifications

Differential Bearing Replacement (G86) — figure 22

11. Remove (wipe out) excess sealant from the seal bore and deflector groove at the locations indicated by arrows, before installing the rear axle shaft seal.
12.  Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (1), Install NEW rear axle shaft seal (2).

Differential Bearing Replacement (G86) — figure 23

13. Rear Axle Shaft (1) » Install

Differential Bearing Replacement (G86) — figure 24

14. Remove (wipe out) excess sealant from the seal bore and deflector groove at the locations indicated by arrows, before installing the rear axle shaft seal.
15.  Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (2), Install NEW rear axle shaft seal (1).

Differential Bearing Replacement (G86) — figure 25

16. Rear Axle Shaft (1) » Install

17. Remove the DT-52902 Rear Drive Module Rotating Fixture (2).

18. Raise the differential carrier.

19. Differential Carrier Rear Bolt (1) » Install and tighten [2x] — Fastener Specifications

Caution

Refer to Torque-to-Yield Fastener Caution.

20. Differential Carrier Front Bolt (1) » Install NEW

21. Differential Carrier Nut (2) » Install and tighten — Fastener Specifications

22. Remove support from the rear differential carrier.

23. Rear Axle Vent Hose (2) » Connect

24. {If equipped} with dual exhaust. 24.1. Spare Wheel Heat Shield (1) » Install 24.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

25. {If equipped} with single exhaust. 25.1. Spare Wheel Heat Shield (1) » Install 25.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

26. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 26.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 26.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 26.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 26.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

27. Reposition the right rear wheel drive shaft.

28. Rear Wheel Drive Shaft Bolt (1) » Install and tighten [8x] — Fastener Specifications

29. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 29.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 29.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 29.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 29.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

30. Reposition the left rear wheel drive shaft.

31. Rear Wheel Drive Shaft Bolt (1) » Install and tighten [8x] — Fastener Specifications

32. Propeller Shaft (1) » Install

33. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 33.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 33.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 33.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 33.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

34. Rear Propeller Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

Differential Bearing Replacement (G86) — figure 26

35. Rear Axle Housing Fill Plug (1) » Remove
36. Fill the rear differential carrier with the appropriate amount and type of axle lubricant: Adhesives, Fluids, Lubricants, and Sealers Approximate Fluid Capacities
37. The gear lubricant level should be 0 - 5 mm (0.0 - 0.20 in) below the bottom of the fill plug opening.

Caution

Refer to Component Fastener Tightening Caution.

38. Rear Axle Housing Fill Plug (1) » Install and tighten — Fastener Specifications
39. Remove the support and lower the vehicle.
40. Install the spare tire.