For 1990-2009 cars

## Rear Axle Assemble RPO (M41)

#### Tools Required

• | J 8107-4 Differential Side Bearing Remover Plug

• | J 8092 Driver Handle

• | J 8614-01 Flange and Pulley Holding Tool

• | J 37758 Pinion Outer Race Installer

• | J 37759 Pinion Inner Bearing Race Installer

• | J 35138 Side Gear Thrust Play Tool

• | J 38891 Wheel Speed Sensor Ring Installer

• | J 38890 Differential Torque Check Tool

• | J 8001 Dial Indicator Set

• | J 25273 Pinion Seal Installer

• | J 6133-A Bearing Race Installer

### Installation Procedure

1. Install the following in the right differential case:

• | Right side gear and washers

• | Differential pinion gears (2) and washers (1)

• | Cross shafts

• | Pinion cross shaft joint

2. Measure the right differential side gear (1) end play using the J 8001 .
3. Insert fingers through the bottom openings of the right differential case (2) half and move the right differential side gear (1) up and down while observing the J 8001 .

The right differential side gear end play should measure 12-37 mm (0.005-0.014 in).

4. Replace the selective shim with the appropriate size to obtain correct end play, if the right differential side gear end play is too high or low.
5. Install the cross shaft roll pins into the right differential case (4) half. The roll pin ends should be flush with the right differential case surface.
6. Install the left differential side gear (1) and washers (2) into the right differential case.

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.

7. Install the left differential case half and ring gear (2) to the right differential case half. Secure with 10 bolts (1).

Tighten
Tighten the ring gear bolts to 90 N·m (65 lb ft).

8. Measure the left differential side gear end play using the J 8001 the J 35138 .
9. Insert the J 35138 in through the left axle shaft differential case (1) bore.
10. Adjust the J 35138 until the J 35138 has a firm grasp on the left differential side gear.
11. Move the J 35138 up and down while observing the J 8001 . The left differential side gear end play should measure 12-37 mm (0.005-0.014 in).
12. Replace the selective shim with the appropriate size to obtain the correct end play if the left differential side end play is too high or low.
13. Install the side gear preload to the left differential case (1) using the J 38890 .
14. Insert the J 38890 into either side bearing with a torque wrench.
15. Measure the side bearing preload.

The maximum side gear preload 2.4 N·m (21 lb in).

Important: After the correct end play and preload has been obtained, remove the ring gear bolts and apply GM P/N 12345493 (Canadian P/N 10953488), or the equivalent, to the threaded portion of each ring gear bolt and install into the differential case assembly.

16. Inspect the side and differential pinion gears for foreign material or damage if the preload exceeds the specification.

Tighten
Tighten the ring gear bolts to 90 N·m (65 lb ft).

17. Install the right differential side bearing (1) on the right side of the differential case assembly (2) using the J 37758 with the J 8092 .
18. Place the differential case assembly on a hydraulic press using the J 8107-4 for support.
19. Place the right side bearing on the right differential case with the taper side up using the J 37759 with the J 8092 .
20. Slowly press the right differential side bearing onto the right differential case.
21. Install the left differential case (2) to the left side of the differential case assembly using the J 37758 with the J 8092 and the J 8107-4 .
22. Place the differential case assembly on a hydraulic press with the J 8107-4 for support and to protect the right differential side bearing (1).
23. Place the left differential side bearing on the left differential case with the taper side up using the J 37758 with the J 8092 .
24. Slowly press the left differential side bearing onto the left differential case.
25. Install the inner pinion bearing race using the J 37759 and the J 8092 .
26. Place the differential carrier (1) on a hydraulic press.
27. Position the inner pinion bearing race over its bore.
28. Use the J 37759 inner with the J 8092 to slowly press the inner pinion bearing race evenly into the differential carrier.
29. Install the outer pinion bearing race (1) using the J 37758 with the J 8092 .
30. Place the differential carrier (2) on a hydraulic press.
31. Position the outer pinion bearing race over its bore.
32. Press the outer pinion bearing race slowly and evenly into the differential carrier using the J 37758 with the J 8092 .
33. Install a pinion selective shim (2) onto the pinion gear shaft.
34. Install the pinion bearing (1) onto the pinion gear shaft. Use the J 6133-A .
35. Place the pinion gear (3) on a hydraulic press.
36. Install the inner pinion bearing on the pinion gear shift shaft with the tapered side facing away from the pinion gear.
37. Place the J 6133-A .
38. Install a new collapsible spacer (4) onto the pinion gear shaft with the short shank toward the pinion gear.
39. Install the outer pinion bearing (3) and the pinion gear (5) into the differential carrier (2).
40. Install a new pinion oil seal into the differential carrier using the J 25273 .
41. Apply wheel bearing lubricant GM P/N 1051344 (Canadian P/N 993037), or equivalent, to the new pinion oil seal lip.

Important: Do not overtighten the pinion flange nut when adjusting the bearing preload. Tighten the pinion flange nut gradually while taking frequent pinion bearing preload measurements with a torque wrench. If overtightening exists the collapsible spacer will crush requiring a new collapsible spacer before pinion bearing preload can be properly adjusted.

42. Adjust the pinion bearing preload using the J 8614-01 .

Tighten
Tighten the nut gradually in increments of 5 N·m (44 lb in).

43. Between each increments of tightening, remove the J 8614-01 .
44. Measure the bearing preload using a torque wrench and a 27 mm socket (2).
45. The pinion gear should require 1.2 N·m (11 lb in) in order to rotate.
46. If the pinion bearing preload is less than specified, repeat the adjustment procedure until proper pinion bearing preload has been attained.
47. Install the pinion flange nut.
48. Install the side bearing races onto the differential side bearings.
49. Install the differential assembly into the differential carrier.
50. Install both side bearing adjusters (2) on the side bearing races.
51. Install both side bearing caps onto differential carrier, secure with the four side bearing cap bolts.

Tighten
Tighten differential side bearing cap bolts to 15 N·m (11 lb ft).

## Rear Axle Assemble RPO (M59)

#### Tools Required

• | J 6133-A Bearing Race Installer

• | J 8092 Driver Handle

• | J 8614-01 Flange and Pulley Holding Tool

• | J 37758 Countershaft Rear Plug Installer

• | J 37759 Pinion Inner Bearing Race Installer

• | J 35138 Side Gear Thrust Play Tool

• | J 38890 Differential Torque Check Tool

• | J 8001 Dial Indicator Set

• | J 25273 Pinion Seal Installer

### Installation Procedure

1. Install the following in the right differential case:

• | Right side gear and washers

• | Differential pinion gears (2) and washers (1)

• | Cross shafts

• | Pinion cross shaft joint

2. Measure the right differential side gear (1) end play using the J 8001 .
3. Insert fingers through the bottom openings of the right differential case (2) half and move the right differential side gear (1) up and down while observing the J 8001 .

The right differential side gear end play should measure 12-37 mm (0.005-0.014 in).

4. Replace the selective shim with the appropriate size to obtain correct end play, if the right differential side gear end play is too high or low.
5. Install the cross shaft roll pins into the right differential case (4) half. The roll pin ends should be flush with the right differential case surface.
6. Install the left differential side gear (1) and washers (2) into the right differential case.

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.

7. Install the ring gear to the differential case half. Secure with 10 bolts (1)

Tighten
Tighten the ring gear bolts to 90 N·m (65 lb ft).

8. Secure the 8 bolts (1) to join both differential case halves.

Tighten
Tighten the bolts to 41 N·m (30 lb ft).

9. Measure the left differential side gear end play using the J 8001 the J 35138 .
10. Insert the J 35138 in through the left axle shaft differential case (1) bore.
11. Adjust the J 35138 until the J 35138 has a firm grasp on the left differential side gear.
12. Move the J 35138 up and down while observing the J 8001 . The left differential side gear end play should measure 12-37 mm (0.005-0.014 in).
13. Replace the selective shim with the appropriate size to obtain the correct end play if the left differential side end play is too high or low.
14. Install the side gear preload to the left differential case (1) using the J 38890 .
15. Insert the J 38890 into either side bearing with a torque wrench.
16. Measure the side bearing preload.

The maximum side gear preload 2.4 N·m (21 lb in).

Important: After the correct end play and preload has been obtained, remove the ring gear bolts and apply GM P/N 12345493 (Canadian P/N 10953488), or the equivalent, to the threaded portion of each ring gear bolt and install into the differential case assembly.

17. Inspect the side and differential pinion gears for foreign material or damage if the preload exceeds the specification.

Tighten
Tighten the ring gear bolts to 90 N·m (65 lb ft).

18. Install the right differential side bearing (1) on the right side of the differential case assembly (2) using the J 37758 with the J 8092 .
19. Place the differential case assembly on a hydraulic press using the J 8107-4 for support.
20. Place the right side bearing on the right differential case with the taper side up using the J 37759 with the J 8092 .
21. Slowly press the right differential side bearing onto the right differential case.
22. Install the left differential case (2) to the left side of the differential case assembly using the J 37758 with the J 8092 and the J 8107-4 .
23. Place the differential case assembly on a hydraulic press with the J 8107-4 for support and to protect the right differential side bearing (1).
24. Place the left differential side bearing on the left differential case with the taper side up using the J 37758 with the J 8092 .
25. Slowly press the left differential side bearing onto the left differential case.
26. Install the inner pinion bearing race using the J 37759 and the J 8092 .
27. Place the differential carrier (1) on a hydraulic press.
28. Position the inner pinion bearing race over its bore.
29. Use the J 37759 inner with the J 8092 to slowly press the inner pinion bearing race evenly into the differential carrier.
30. Install the outer pinion bearing race (1) using the J 37758 with the J 8092 .
31. Place the differential carrier (2) on a hydraulic press.
32. Position the outer pinion bearing race over its bore.
33. Press the outer pinion bearing race slowly and evenly into the differential carrier using the J 37758 with the J 8092 .
34. Install a pinion selective shim (2) onto the pinion gear shaft.
35. Install the pinion bearing (1) onto the pinion gear shaft. Use the J 6133-A .
36. Place the pinion gear (3) on a hydraulic press.
37. Install the inner pinion bearing on the pinion gear shift shaft with the tapered side facing away from the pinion gear.
38. Place the J 6133-A .
39. Install a new collapsible spacer (4) onto the pinion gear shaft with the short shank toward the pinion gear.
40. Install the outer pinion bearing (3) and the pinion gear (5) into the differential carrier (2).
41. Install a new pinion oil seal into the differential carrier using the J 25273 .
42. Apply wheel bearing lubricant GM P/N 1051344 (Canadian P/N 993037), or equivalent, to the new pinion oil seal lip.

Important: Do not overtighten the pinion flange nut when adjusting the bearing preload. Tighten the pinion flange nut gradually while taking frequent pinion bearing preload measurements with a torque wrench. If overtightening exists the collapsible spacer will crush requiring a new collapsible spacer before pinion bearing preload can be properly adjusted.

43. Adjust the pinion bearing preload using the J 8614-01 .

Tighten
Tighten the nut gradually in increments of 5 N·m (44 lb in).

44. Between each increments of tightening, remove the J 8614-01 .
45. Measure the bearing preload using a torque wrench and a 27 mm socket (2).
46. The pinion gear should require 1.2 N·m (11 lb in) in order to rotate.
47. If the pinion bearing preload is less than specified, repeat the adjustment procedure until proper pinion bearing preload has been attained.
48. Install the pinion flange nut.
49. Install the side bearing races onto the differential side bearings.
50. Install the differential assembly into the differential carrier.
51. Install both side bearing adjusters (2) on the side bearing races.
52. Install both side bearing caps onto differential carrier, secure with the four side bearing cap bolts.

Tighten
Tighten differential side bearing cap bolts to 15 N·m (11 lb ft).