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Home › Pontiac › 2001 › Aztek Base, AWD › Repair and Diagnosis › External Pages › Different car › Section 1438 (Rear Drive Axle) › Repair Instructions › Differential Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Aztek and 2002 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Installing Torque Tube To Differential
G01759816Courtesy of GENERAL MOTORS CORP.
  1. Install the torque tube (1) to the differential. Refer to Torque Tube Assembly Replacement .
  2. Install the rear differential and torque tube assembly to the suspension cradle.
    Fig 2: Installing Differential Carrier Mounts, Washers, Bolts & Nuts To Differential
    G01759817Courtesy of GENERAL MOTORS CORP.

    Simultaneously guide the left wheel drive shaft onto the differential output shaft while positioning the differential assembly to the suspension cradle.

  3. Place an adjustable support under the torque tube.
  4. Ensure that the left wheel drive shaft is fully engaged to the differential output shaft.
    NOTE: Refer to FASTENER NOTICE .
  5. Install the differential carrier mounts (3,4) washers (2), bolts (5), and nuts (1) to the differential.

    Tighten  Tighten the differential carrier-to-cradle mounting bolts to 50 N.m (37 lb ft).

  6. Install the torque tube bracket-to-body (5).
    Fig 3: Installing Torque Tube Bracket-To-Body Bolts
    G01759818Courtesy of GENERAL MOTORS CORP.

    Tighten 

    • Tighten the torque tube bracket-to-body bolts to 55 N.m (41 lb ft).
    • Tighten the torque tube-to-bracket through bolt and nut to 64 N.m (47 lb ft).
  7. Install the front propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
  8. Install the right rear wheel drive shaft. Refer to AXLE SHAFTS .
  9. Install the right rear tire and wheel assembly. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
  10. Install the differential drain plug (2) and gasket to the differential.
    Fig 4: Installing Differential Fill Plug & Differential Drain Plug
    G01759819Courtesy of GENERAL MOTORS CORP.

    Tighten  Tighten the drain plug to 32 N.m (23 lb ft).

  11. Remove the differential fill plug (1).
  12. Fill the axle with synthetic gear oil. Refer to Lubricant Change .
  13. Inspect the differential oil level to ensure it is even with, to no lower than, 6 mm (0.25 in) below the opening of the fill hole.
  14. Install the differential fill plug (1) gasket.

    Tighten  Tighten the fill plug to 32 N.m (23 lb ft).

  15. Connect the electrical connector to the clutch pump check valve.
  16. Remove the adjustable support from the torque tube.
  17. Lower the vehicle.
  18. Operate the vehicle making tight left, then right turns in order to engage the all-wheel-drive system and distribute the gear oil throughout the differential.
  19. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  20. Remove the differential fill plug.
  21. Fill the axle with synthetic gear oil. Refer to Lubricant Change .
  22. Inspect the differential oil level to ensure it is even with, to no lower than, 6 mm (0.25 in) below the opening of the fill hole.
  23. Install the differential fill plug and gasket.

    Tighten  Tighten the fill plug to 32 N.m (23 lb ft).

  24. Lower the vehicle.
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