Rear Axle Housing Replacement (G96)

Single Use Fasteners and Components Differential Carrier Bushing Differential Carrier Front Bolt Differential Drive Pinion Gear Bearing Spacer Differential Drive Pinion Gear Nut Differential Drive Pinion Gear Seal Rear Axle Shaft Seal [2x] Rear Wheel Drive Module Differential Clutch Input Shaft Seal Special Tools DT-22888-D Side Bearing Remover Kit DT-22912-B Bearing Remover DT-24433 Pinion Cone and Side Bearing Installer DT-3289-20 Holding Fixture DT-48728 Bearing Installer DT-50315 Hardware Kit DT-52506 Pinion Flange Holder and Remover DT-52898 Pinion Bearing Cup Installer DT-52898-10 Pinion Bearing Cup Replacer Adapter DT-52899 Rear Drive Module Mount Bushing Replacer DT-52899-5 Bushing Replacer Adapter DT-52902 Rear Drive Module Rotating Fixture DT-52902-5 Rear Drive Module Rotating Fixture Hardware DT-52903 Axle Flange Remover DT-52904 Input/Pinion Seal Installer 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 GE-8433-1 Puller Bar Equivalent regional tools: Special Tools Removal Procedure

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

Rear Axle Housing 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.

Rear Axle Housing Replacement (G96) — figure 2

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

Rear Axle Housing Replacement (G96) — figure 3

8. Propeller Shaft (1) » Remove

Rear Axle Housing Replacement (G96) — figure 4

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

Rear Axle Housing Replacement (G96) — figure 5

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

Rear Axle Housing Replacement (G96) — figure 6

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

Rear Axle Housing 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

Rear Axle Housing 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

Rear Axle Housing Replacement (G96) — figure 9

16. Rear Axle Vent Hose (2) » Disconnect

Rear Axle Housing 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.

Rear Axle Housing Replacement (G96) — figure 11

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

Rear Axle Housing Replacement (G96) — figure 12

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

Rear Axle Housing 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).

Rear Axle Housing 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).

Rear Axle Housing Replacement (G96) — figure 15

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

Rear Axle Housing 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

Rear Axle Housing 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).

Rear Axle Housing Replacement (G96) — figure 18

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

Rear Axle Housing 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).

Rear Axle Housing Replacement (G96) — figure 20

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

Rear Axle Housing 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

Rear Axle Housing Replacement (G96) — figure 22

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

Rear Axle Housing Replacement (G96) — figure 23

44. Using DT-50315 Hardware Kit (3), GE-8433-1 Puller Bar (4), DT-22912-B Bearing Remover  (5), and DT-8107-4 Side Bearing Puller Pilot  (6), Remove the differential bearing (1).
45. Using DT-22888-20A Universal Two Jaw Puller (7) with DT-22888-30 Side Bearing Puller Legs  (8) and DT-8107-4 Side Bearing Puller Pilot (9), Remove the differential bearing (2).

Rear Axle Housing Replacement (G96) — figure 24

46. Using DT-52506 Pinion Flange Holder and Remover (2), Remove and DISCARD the differential drive pinion gear nut (1).

Rear Axle Housing Replacement (G96) — figure 25

Note

Be careful not to damage the slinger when removing the pinion gear yoke assembly.

47. Using DT-52506 Pinion Flange Holder and Remover (2), Remove the differential drive pinion gear yoke (1).

Rear Axle Housing Replacement (G96) — figure 26

48. Differential Drive Pinion Gear Seal (1) » Remove and DISCARD

Rear Axle Housing Replacement (G96) — figure 27

49. Differential Drive Pinion Gear Washer (1) » Remove
50. Differential Drive Pinion Gear Outer Bearing (2) » Remove

Rear Axle Housing Replacement (G96) — figure 28

51. Differential Drive Pinion Gear (1) » Remove

Rear Axle Housing Replacement (G96) — figure 29

52. Differential Drive Pinion Gear Bearing Spacer (1) » Remove and DISCARD

Rear Axle Housing Replacement (G96) — figure 30

53. Using DT-22912-B Bearing Remover (1), Remove the differential drive pinion gear inner bearing (2).

Rear Axle Housing Replacement (G96) — figure 31

54. Rear Axle Housing Chip Collector Magnet (1) » Remove

Rear Axle Housing Replacement (G96) — figure 32

55. Rear Wheel Drive Module Differential Clutch Input Shaft Retaining Ring (2) » Remove
56. Locking Differential Side Gear (3) » Remove
57. Electric Differential Drive Motor Rotor Shaft (5) » Remove
58. Rear Wheel Drive Module Differential Clutch Input Shaft Seal (4) » Remove and DISCARD Cleaning and Inspection Procedure - Required
59. Clean any debris and material from the axle housing.
60. Clean the rear axle housing chip collector magnet.
61. Inspect the axle components for damage and burrs, if any damage or burrs are found replacement of the affected axle components would be necessary.
62. Clean off the old sealant from the rear axle housing and rear axle housing cover using Acetone, followed by Isopropyl Alcohol. Installation Procedure

Rear Axle Housing Replacement (G96) — figure 33

1.  1. Using the DT-52899-5 Bushing Replacer Adapter and DT-52899 Rear Drive Module Mount Bushing Replacer (2), Install NEW the differential carrier bushing (1).

2. Rear Wheel Drive Module Differential Clutch Input Shaft Seal (4) » Install NEW

3. Electric Differential Drive Motor Rotor Shaft (5) » Install

4. Locking Differential Side Gear (3) » Install

5. Rear Wheel Drive Module Differential Clutch Input Shaft Retaining Ring (2) » Install

6. Rear Axle Vent (1) » Install

7. Rear Axle Housing Chip Collector Magnet (1) » Install

Rear Axle Housing Replacement (G96) — figure 34

8. Using DT-52898-4 (3), DT-52898-10 (4), and DT-52898-5 (2), Install the differential drive pinion inner bearing cup (1).

Rear Axle Housing Replacement (G96) — figure 35

9. Using DT-52898-10 (4), DT-52898-3 (3), and DT-52898-5 (2), Install the differential drive pinion outer bearing cup (1).

Rear Axle Housing Replacement (G96) — figure 36

10. Measure the thickness needed for the differential drive pinion bearing shims, refer to Pinion Depth Adjustment.

11. Using DT-24433 Pinion Cone and Side Bearing Installer (1), Install NEW differential drive pinion gear inner bearing (2) onto the differential drive pinion gear with the appropriate shim.

12. Differential Drive Pinion Gear Bearing Spacer (1) » Install NEW

Note

The differential drive pinion gear washer (1) is directional. The stepped surface must be installed facing the bearing.

13. Differential Drive Pinion Gear Outer Bearing (2) » Install
14. Differential Drive Pinion Gear Washer (1) » Install

Rear Axle Housing Replacement (G96) — figure 37

15. Using DT-52904 Input/Pinion Seal Installer (1), Install NEW differential drive pinion gear seal  (2).

16. Differential Drive Pinion Gear (1) » Install

17. Apply sealant to the pinion yoke splines. Adhesives, Fluids, Lubricants, and Sealers

18. Apply grease to the pinion seal where it will contact the pinion gear yoke slinger. Adhesives, Fluids, Lubricants, and Sealers

Rear Axle Housing Replacement (G96) — figure 38

Note

Be careful not to damage the slinger when installing the pinion gear yoke assembly.

19. Differential Drive Pinion Gear Yoke (1) » Install

Caution

Refer to Torque-to-Yield Fastener Caution.

Caution

Refer to Fastener Caution.

20. Using DT-52506 Pinion Flange Holder and Remover (2), Install NEW and tighten the differential drive pinion gear nut (1). Fastener Specifications

Rear Axle Housing Replacement (G96) — figure 39

21. Using DT-48728 Bearing Installer (1) and a shop press, Install 2 differential bearing (2).
22. Measure the thickness needed for the differential bearing shims, refer to Differential Carrier Bearing Preload Adjustment.
23. 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.

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

Rear Axle Housing Replacement (G96) — figure 40

Note

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

25. 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.

26. Rear Axle Housing (8) » Install

27. 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: 27.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 27.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 27.3. Remove loose debris from internal and external threads using compressed air. 27.4. 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

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

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

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

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

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

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

34. Differential Bearing Shim (2) » Install

35. Differential Bearing Retaining Ring (1) » Install

Rear Axle Housing Replacement (G96) — figure 41

36. 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).

37. 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.

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

Rear Axle Housing Replacement (G96) — figure 42

39. 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.
40.  Using the DT-52906 Output Seal Installer - LH/Motor (2) and GE-8092 Driver Handle (3), Install NEW rear axle shaft seal (1).

Rear Axle Housing Replacement (G96) — figure 43

41. Rear Axle Shaft (1) » Install

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

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

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

Rear Axle Housing Replacement (G96) — figure 44

45. 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.
46.  Using the DT-52905 Output Seal Installer - RH (2) and GE-8092 Driver Handle (1), Install NEW rear axle shaft seal (3).

Rear Axle Housing Replacement (G96) — figure 45

47. Rear Axle Shaft (1) » Install

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

49. Raise the differential carrier.

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

Caution

Refer to Torque-to-Yield Fastener Caution.

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

Note

Some components not shown for graphic clarity.

54. Differential Carrier Ground Cable » Reposition

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

56. Rear Axle Vent Hose (2) » Connect

57. {If equipped} with dual exhaust. 57.1. Spare Wheel Heat Shield (1) » Install 57.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

58. {If equipped} with single exhaust. 58.1. Spare Wheel Heat Shield (1) » Install 58.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

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

60. 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: 60.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 60.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 60.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 60.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

61. Reposition the right rear wheel drive shaft.

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

63. 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: 63.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 63.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 63.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 63.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

64. Reposition the left rear wheel drive shaft.

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

66. Propeller Shaft (1) » Install

67. 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: 67.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 67.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 67.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 67.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

Caution

Refer to Component Fastener Tightening Caution.

69. Rear Axle Housing Drain Plug (2) Install and tighten — Fastener Specifications
70. Fill the rear differential carrier with the appropriate amount and type of axle lubricant: Adhesives, Fluids, Lubricants, and Sealers Approximate Fluid Capacities
71. 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.

72. Rear Axle Housing Fill Plug (3) » Install and tighten — Fastener Specifications
73. Remove the support and lower the vehicle.
74. Install the spare tire.