For 1990-2009 cars

### Assembly Procedure

1. Install the thrust washers.
2. Install the following components into the differential case:

• | The thrust washers

• | The side gears

• | The pinion gears

3. Install the pinion shaft.
4. Measure the side gear backlash while holding one pinion gear toward the carrier.
5. Make sure the side gear backlash falls within standard backlash range.

Standard backlash range is 0.05-0.20 mm (0.0020-0.0079 in).

6. Select washers of the same size on both sides.
7. Select thrust washers that ensure that the backlash falls within standard range. Refer to Differential Thrust Washer Specifications .
8. If the backlash is not within standard range, install a new thrust washer.
9. Install the pinions and the shaft.
10. Use a hammer and a punch in order to drive the lock pin through the carrier and the hole in the pinion shaft.
11. Use a hammer and punch in order to stake the differential carrier.
12. Install the following components onto the right side bearing:

• | The outer race (2)

• | The adjusting shim (1)

• | If the shim has a thickness of less than 2.40 mm (0.0945 in), replace the shim.

13. Install the differential carrier assembly (4,5) into the case (1).
14. Install the O-ring (6) onto the left bearing retainer (9).
15. Install the left bearing retainer (9) onto the case (1). Tap in the retainer while holding the differential carrier centered.
16. Clean the threads of the left bearing retainer bolts.
17. Coat the threads of the left bearing retainer bolts with GM P/N 1052624 Loctite.
18. Hand tighten the bolts while turning the ring gear.

Tighten the bolts evenly and gradually.

19. Install the right side bearing cap (2) .

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

20. Hand tighten the bolts while turning the ring gear.

Tighten the bolts evenly and gradually.

Tighten
Tighten the left bearing retainer bolts to 19 N·m (14 lb ft).

21. Measure the total preload. Refer to Differential Adjustment .

Tighten
Tighten the right side bearing cap bolts to 49 N·m (36 lb ft).

### Installation Procedure

1. Install the carrier cover (1).
2. Clean the threads of the carrier cover bolts.
3. Coat the threads of the carrier cover bolts with GM P/N 1052624 Loctite.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the carrier cover over the gasket.

Tighten
Tighten the carrier cover bolts to 25 N·m (18 lb ft).

5. For overhaul of the complete transaxle assembly, refer to Transmission Assemble .
6. Assemble the transaxle. Refer to Transmission Assemble