Differential Carrier Assembly Replacement (G96)

Single Use Fasteners and Components Differential Carrier Front Bolt Removal Procedure

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

Differential Carrier Assembly Replacement (G96) — figure 1

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

Differential Carrier Assembly Replacement (G96) — figure 2

4. Propeller Shaft (1) » Remove

Differential Carrier Assembly Replacement (G96) — figure 3

5. Rear Wheel Drive Shaft Bolt (1) » Remove [8x]
6. Reposition the right rear wheel drive shaft downwards.

Differential Carrier Assembly Replacement (G96) — figure 4

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

Differential Carrier Assembly Replacement (G96) — figure 5

9. Disconnect the limited slip differential clutch motor electrical connector (1)

Differential Carrier Assembly Replacement (G96) — figure 6

10. {If equipped} with dual exhaust. 10.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 10.2. Spare Wheel Heat Shield (1) » Remove

Differential Carrier Assembly Replacement (G96) — figure 7

11. {If equipped} with single exhaust. 11.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 11.2. Spare Wheel Heat Shield (1) » Remove

Differential Carrier Assembly Replacement (G96) — figure 8

12. Rear Axle Vent Hose (2) » Disconnect

Differential Carrier Assembly Replacement (G96) — figure 9

Note

Some components not shown for graphic clarity.

13. Battery Cable Terminal Bolt (1) » Remove
14. Differential Carrier Ground Cable » Reposition
15. Support the rear differential carrier.

Differential Carrier Assembly Replacement (G96) — figure 10

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

Differential Carrier Assembly Replacement (G96) — figure 11

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

Caution

Refer to Fastener Caution.

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

Caution

Refer to Torque-to-Yield Fastener Caution.

3. Differential Carrier Front Bolt (1) » Install NEW
4. Differential Carrier Nut (2) » Install and tighten — Fastener Specifications
5. Remove support from the rear differential carrier.

Note

Some components not shown for graphic clarity.

6. Differential Carrier Ground Cable » Reposition

7. Battery Cable Terminal Bolt (1) » Install and tighten — Fastener Specifications

8. Rear Axle Vent Hose (2) » Connect

9. {If equipped} with dual exhaust. 9.1. Spare Wheel Heat Shield (1) » Install 9.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

10. {If equipped} with single exhaust. 10.1. Spare Wheel Heat Shield (1) » Install 10.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

11. Connect the limited slip differential clutch motor electrical connector (1)

12. 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: 12.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 12.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 12.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 12.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

13. Reposition the right rear wheel drive shaft.

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

15. 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: 15.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 15.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 15.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 15.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

16. Reposition the left rear wheel drive shaft.

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

18. Propeller Shaft (1) » Install

19. 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: 19.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 19.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 19.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 19.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

Differential Carrier Assembly Replacement (G96) — figure 12

21. Rear Axle Housing Fill Plug (3) » Remove
22. Inspect the gear lubricant level, it should be 1-2 mm (0.039-0.079 in) below the bottom of the fill plug opening.
23. If the level is low, add gear lubricant until the level is 1-2 mm (0.039-0.079 in) below the bottom of the fill plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

24. Rear Axle Housing Fill Plug (3) » Install and tighten — Fastener Specifications
25. Remove the support and lower the vehicle.
26. Install the spare tire.