Differential Replacement (G96)

Single Use Fasteners and Components Differential Carrier Front Bolt Differential Ring Gear Bolt [12x] Rear Axle Shaft Seal [2x] Special Tools DT-3289-20 Holding Fixture DT-48728 Bearing Installer DT-52902 Rear Drive Module Rotating Fixture DT-52902-5 Rear Drive Module Rotating Fixture Hardware DT-52903 Axle Flange Remover DT-52905 Output Seal Installer - RH DT-52906 Output Seal Installer - LH/Motor DT-53030 Axis Snap Ring Installer GE-02619-A Slide Hammer w/Adapter GE-8092 Driver Handle Equivalent regional tools: Special Tools Removal Procedure

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

Differential Replacement (G96) — figure 1

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

Differential Replacement (G96) — figure 2

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

Differential Replacement (G96) — figure 3

8. Propeller Shaft (1) » Remove

Differential Replacement (G96) — figure 4

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

Differential Replacement (G96) — figure 5

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

Differential Replacement (G96) — figure 6

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

Differential Replacement (G96) — figure 7

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

Differential Replacement (G96) — figure 8

15. {If equipped} with single exhaust. 15.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 15.2. Spare Wheel Heat Shield (1) » Remove

Differential Replacement (G96) — figure 9

16. Rear Axle Vent Hose (2) » Disconnect

Differential Replacement (G96) — figure 10

Note

Some components not shown for graphic clarity.

17. Battery Cable Terminal Bolt (1) » Remove
18. Differential Carrier Ground Cable » Reposition
19. Support the rear differential carrier.

Differential Replacement (G96) — figure 11

20. Differential Carrier Nut (2) » Remove
21. Differential Carrier Front Bolt (1) » Remove and DISCARD

Differential Replacement (G96) — figure 12

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

Differential Replacement (G96) — figure 13

24. Install the DT-52902 Rear Drive Module Rotating Fixture (2) to the rear axle housing using DT- 52902-5 Rear Drive Module Rotating Fixture Hardware (3) and attach to the DT-3289-20 Holding Fixture (1).

Differential Replacement (G96) — figure 14

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

Differential Replacement (G96) — figure 15

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

Differential Replacement (G96) — figure 16

27. Limited Slip Differential Clutch Motor Bolt (1) » Remove [4x]
28. Limited Slip Differential Clutch Motor (2) » Remove
29. Limited Slip Differential Clutch Motor Seal (3) » Remove

Differential Replacement (G96) — figure 17

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

Differential Replacement (G96) — figure 18

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

Differential Replacement (G96) — figure 19

32. Using DT-53030 Axis Snap Ring Installer (2) and a secondary differential bearing retaining ring (1) apply moderate pressure to free the differential bearing retaining ring (3).
33. Remove the secondary differential bearing retaining ring (1) and DT-53030 Axis Snap Ring Installer (2).

Differential Replacement (G96) — figure 20

34. Differential Bearing Retaining Ring (1) » Remove
35. Differential Bearing Shim (2) » Remove

Differential Replacement (G96) — figure 21

36. Differential Carrier Nut (1) » Remove
37. Remove the 2 differential carrier bracket washers (2) and the differential carrier ground cable  (3).
38. Battery Negative Cable Ground Stud (4) » Remove
39. Differential Carrier Cover Bolt (7) » Remove [5x]
40. Rear Axle Housing Cover Bolt (5) » Remove [2x]
41. Rear Axle Housing Cover Bolt (6) » Remove [2x]
42. Rear Axle Housing (8) » Remove

Differential Replacement (G96) — figure 22

43. Remove the differential (3), bearing races (2), and shim (1).

Differential Replacement (G96) — figure 23

Note

The differential ring gear bolts have left-hand threads.

44. Differential Ring Gear Bolt (1) » Remove and DISCARD [12x]

45. Differential Ring Gear (2) » Remove Cleaning and Inspection Procedure - Required

46. Clean any debris and material from the axle housing.

47. Inspect the axle housing for damage and burrs, if any damage or burrs are found replacement of the axle housing would be necessary.

48. Clean off the old sealant from the rear axle housing and rear axle housing cover using Acetone, followed by Isopropyl Alcohol. Installation Procedure

49. Differential Ring Gear (2) » Install

Caution

Refer to Fastener Caution.

Note

The differential ring gear bolts have left-hand threads. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Tighten the differential ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

2. Differential Ring Gear Bolt (1) » Install NEW and tighten [12x] — Fastener Specifications

Differential Replacement (G96) — figure 24

3. Using DT-48728 Bearing Installer (1) and a shop press, Install 2 differential bearing (2).
4. Measure the thickness needed for the differential bearing shims, refer to Differential Carrier Bearing Preload Adjustment.
5. Measure and adjust the backlash, refer to Backlash Adjustment.

Note

A dead blow hammer can be used to help seat the differential and shim. The ball ramp fork must be aligned to the actuator pin (4) upon installation.

6. Install the differential (3), bearing races (2), and shim (1).

Differential Replacement (G96) — figure 25

Note

Install and align the rear axle housing within 15 minutes of applying sealer.

7. Apply a 2 mm (0.08 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 (0.08 in) high and 2 mm (0.079 in) from the chamfer.

Note

The rear axle housing (8) must be completely seated against the other half of the rear axle housing before installing the rear axle housing cover bolts.

8. Rear Axle Housing (8) » Install

9. 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: 9.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 9.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 9.3. Remove loose debris from internal and external threads using compressed air. 9.4. Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation. Adhesives, Fluids, Lubricants, and Sealers

10. Rear Axle Housing Cover Bolt (6) » Install and tighten [2x] — Fastener Specifications

11. Rear Axle Housing Cover Bolt (5) » Install and tighten [2x] — Fastener Specifications

12. Differential Carrier Cover Bolt (7) » Install and tighten [5x] — Fastener Specifications

13. Battery Negative Cable Ground Stud (4) » Install and tighten — Fastener Specifications

14. Install the 2 differential carrier bracket washers (2) and the differential carrier ground cable (3) match the removal position of the cable.

15. Differential Carrier Nut (1) » Install and tighten — Fastener Specifications

16. Differential Bearing Shim (2) » Install

17. Differential Bearing Retaining Ring (1) » Install

Differential Replacement (G96) — figure 26

18. Using DT-53030 Axis Snap Ring Installer (2) verify the differential bearing retaining ring (1) is fully seated. There should be a minimum 16.55 mm (0.652 in) gap between the ends of the differential bearing retaining ring (1).

19. If the differential bearing retaining ring is not fully seated, use DT-53030 Axis Snap Ring Installer (2) and a secondary differential bearing retaining ring (1) to apply moderate pressure to the differential bearing retaining ring (3) to preload the differential bearings allowing the differential bearing retaining ring to seat.

20. If necessary, remove the secondary differential bearing retaining ring (1) and DT-53030 Axis Snap Ring Installer (2).

Differential Replacement (G96) — figure 27

21. 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.
22.  Using the DT-52906 Output Seal Installer - LH/Motor (2) and GE-8092 Driver Handle (3), Install NEW rear axle shaft seal (1).

Differential Replacement (G96) — figure 28

23. Rear Axle Shaft (1) » Install

24. Limited Slip Differential Clutch Motor Seal (3) » Install

25. Limited Slip Differential Clutch Motor (2) » Install

26. Limited Slip Differential Clutch Motor Bolt (1) » Install and tighten [4x] — Fastener Specifications

Differential Replacement (G96) — figure 29

27. 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.
28.  Using the DT-52905 Output Seal Installer - RH (2) and GE-8092 Driver Handle (1), Install NEW rear axle shaft seal (3).

Differential Replacement (G96) — figure 30

29. Rear Axle Shaft (1) » Install

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

31. Raise the differential carrier.

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

Caution

Refer to Torque-to-Yield Fastener Caution.

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

Note

Some components not shown for graphic clarity.

36. Differential Carrier Ground Cable » Reposition

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

38. Rear Axle Vent Hose (2) » Connect

39. {If equipped} with dual exhaust. 39.1. Spare Wheel Heat Shield (1) » Install 39.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

40. {If equipped} with single exhaust. 40.1. Spare Wheel Heat Shield (1) » Install 40.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

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

42. 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: 42.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 42.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 42.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 42.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

43. Reposition the right rear wheel drive shaft.

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

45. 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: 45.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 45.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 45.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 45.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

46. Reposition the left rear wheel drive shaft.

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

48. Propeller Shaft (1) » Install

49. 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: 49.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 49.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 49.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 49.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

Caution

Refer to Component Fastener Tightening Caution.

51. Rear Axle Housing Drain Plug (2) Install and tighten — Fastener Specifications
52. Fill the rear differential carrier with the appropriate amount and type of axle lubricant: Adhesives, Fluids, Lubricants, and Sealers Approximate Fluid Capacities
53. The axle lubricant level should be 1 - 2 mm (0.039 - 0.079 in) below the fill plug opening.

Caution

Refer to Component Fastener Tightening Caution.

54. Rear Axle Housing Fill Plug (3) » Install and tighten — Fastener Specifications
55. Remove the support and lower the vehicle.
56. Install the spare tire.