Differential Ring and Pinion Gear Replacement (G86)

Single Use Fasteners and Components Differential Carrier Front Bolt Differential Drive Pinion Gear Nut Differential Drive Pinion Gear Seal Differential Ring Gear Bolt [12x] 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-44412 Pinion Bearing Installer DT-52506 Pinion Flange Holder and Remover DT-52896 Pinion Seal and Side Bearing Installer DT-52898 Pinion Bearing Cup 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 Ring and Pinion Gear 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 Ring and Pinion Gear Replacement (G86) — figure 2

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

Differential Ring and Pinion Gear Replacement (G86) — figure 3

8. Propeller Shaft (1) » Remove

Differential Ring and Pinion Gear Replacement (G86) — figure 4

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

Differential Ring and Pinion Gear Replacement (G86) — figure 5

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

Differential Ring and Pinion Gear 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 Ring and Pinion Gear 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 Ring and Pinion Gear Replacement (G86) — figure 8

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

Differential Ring and Pinion Gear Replacement (G86) — figure 9

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

Differential Ring and Pinion Gear Replacement (G86) — figure 10

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

Differential Ring and Pinion Gear 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 Ring and Pinion Gear 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 Ring and Pinion Gear Replacement (G86) — figure 13

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

Differential Ring and Pinion Gear 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 Ring and Pinion Gear Replacement (G86) — figure 15

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

Differential Ring and Pinion Gear Replacement (G86) — figure 16

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

Differential Ring and Pinion Gear Replacement (G86) — figure 17

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

Differential Ring and Pinion Gear Replacement (G86) — figure 18

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

Differential Ring and Pinion Gear Replacement (G86) — figure 19

Note

The differential ring gear bolts have left-hand threads.

30. Differential Ring Gear Bolt (1) » Remove and DISCARD [12x]
31. Differential Ring Gear (2) » Remove

Differential Ring and Pinion Gear Replacement (G86) — figure 20

32. 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).

Differential Ring and Pinion Gear Replacement (G86) — figure 21

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

Differential Ring and Pinion Gear Replacement (G86) — figure 22

Note

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

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

Differential Ring and Pinion Gear Replacement (G86) — figure 23

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

Differential Ring and Pinion Gear Replacement (G86) — figure 24

36. Differential Drive Pinion Gear Outer Bearing (1) » Remove

Differential Ring and Pinion Gear Replacement (G86) — figure 25

37. Differential Drive Pinion Gear (1) » Remove

Differential Ring and Pinion Gear Replacement (G86) — figure 26

38. Using DT-52898-7 (2), DT-52898-6 (3), and DT-22888-20A Universal Two Jaw Puller (4), Remove the differential drive pinion inner bearing cup (1). Assemble the tools with DT-52898- 6 rotated so that the flat sides are towards the jaws, this allows the jaws to compress and fit through the center of the bearing cup. Once the jaws are through the bearing cup rotate DT- 52898-6 so that it is inline with the jaws, this keep the jaws firmly hooked into the bearing cup. If necessary hold the upper portion of the jaws with a suitable tool to keep the jaws in place during the removal of the bearing cup.

Differential Ring and Pinion Gear Replacement (G86) — figure 27

39. Using DT-52898-8 (4), DT-52898-7 (2), and DT-22888-20A Universal Two Jaw Puller (3), Remove the differential drive pinion outer bearing cup (1). If necessary hold the upper portion of the jaws with a suitable tool to keep the jaws in place during the removal of the bearing cup. Cleaning and Inspection Procedure - Required
40. Clean any debris and material from the axle housing.
41. Inspect the axle housing for damage and burrs, if any damage or burrs are found replacement of the axle housing would be necessary.
42. Clean off the old sealant from the rear axle housing and rear axle housing cover using Acetone, followed by Isopropyl Alcohol. Installation Procedure

Differential Ring and Pinion Gear Replacement (G86) — figure 28

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

Differential Ring and Pinion Gear Replacement (G86) — figure 29

2. {If 9.5 inch RDM} Using DT-52898-1 (4), DT-52898-2 (3), and DT-52898-5 (2), Install the differential drive pinion outer bearing cup (1).
3. {If 9.76 inch RDM} Using DT-52898-1 (4), DT-52898-3 (3), and DT-52898-5 (2), Install the differential drive pinion outer bearing cup (1).

Differential Ring and Pinion Gear Replacement (G86) — figure 30

4. Measure the thickness needed for the differential drive pinion bearing shims, refer to Pinion Depth Adjustment.
5. Using DT-44412 Pinion Bearing Installer (1), Install NEW differential drive pinion gear inner bearing (2) onto the differential drive pinion gear with the appropriate shim.

Differential Ring and Pinion Gear Replacement (G86) — figure 31

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

7. Differential Drive Pinion Gear Outer Bearing (1) » Install

Differential Ring and Pinion Gear Replacement (G86) — figure 32

8. Using DT-52896 Pinion Seal and Side Bearing Installer (1) , Install NEW differential drive pinion gear seal (2).

9. Differential Drive Pinion Gear (1) » Install

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

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

Differential Ring and Pinion Gear Replacement (G86) — figure 33

Note

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

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

Caution

Refer to Torque-to-Yield Fastener Caution.

Caution

Refer to Fastener Caution.

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

14. Differential Ring Gear (2) » Install

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.

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

Differential Ring and Pinion Gear Replacement (G86) — figure 34

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

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

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

19. 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.

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

Differential Ring and Pinion Gear Replacement (G86) — figure 35

Note

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

21. 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.

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

23. 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: 23.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 23.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 23.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 23.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

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

Differential Ring and Pinion Gear Replacement (G86) — figure 36

26. 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.
27.  Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (1), Install NEW rear axle shaft seal (2).

Differential Ring and Pinion Gear Replacement (G86) — figure 37

28. Rear Axle Shaft (1) » Install

Differential Ring and Pinion Gear Replacement (G86) — figure 38

29. 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.
30.  Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (2), Install NEW rear axle shaft seal (1).

Differential Ring and Pinion Gear Replacement (G86) — figure 39

31. Rear Axle Shaft (1) » Install

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

33. Raise the differential carrier.

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

Caution

Refer to Torque-to-Yield Fastener Caution.

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

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

37. Remove support from the rear differential carrier.

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. 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: 41.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 41.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 41.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 41.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

42. Reposition the right rear wheel drive shaft.

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

44. 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: 44.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 44.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 44.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 44.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

45. Reposition the left rear wheel drive shaft.

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

47. Propeller Shaft (1) » Install

48. 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: 48.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 48.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 48.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 48.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

Differential Ring and Pinion Gear Replacement (G86) — figure 40

50. Rear Axle Housing Fill Plug (1) » Remove
51. Fill the rear differential carrier with the appropriate amount and type of axle lubricant: Adhesives, Fluids, Lubricants, and Sealers Approximate Fluid Capacities
52. 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.

53. Rear Axle Housing Fill Plug (1) » Install and tighten — Fastener Specifications
54. Remove the support and lower the vehicle.
55. Install the spare tire.