GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 HUMMER 🢒 2009 🢒 H3 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Differential Overhaul

Disassembly Procedure
  1. Remove the differential side bearings. Refer to Differential Side Bearings Replacement.

    2. Object Number: 866503 Size: SH

    Note: The ring gear bolts have left-hand threads.

  2. Remove and discard the ring gear bolts.

    3. Object Number: 866502 Size: SH

    Caution: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.

    Note: 

  3. Remove the ring gear from the differential case.

    4. Drive the ring gear off with a brass drift if necessary.


    Object Number: 680404 Size: SH
  4. Mark the pinion gears top and bottom and the differential side gears left and right.
  5. Remove the pinion shaft lock bolt.
  6. Remove the pinion shaft.
  7. Roll the differential pinion gears out of the case with the pinion gear thrust washers.
  8. Remove the differential side gears and the side gear thrust washers.

Assembly Procedure
  1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations.
  2. Install the differential side gear thrust washers to the differential side gears.
  3. Install the differential side gears and thrust washers into the differential case.

    4. If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.


    Object Number: 680404 Size: SH
  4. Position one pinion gear between the differential side gears.
  5. Position the second pinion gear between the differential side gears directly opposite the of the first gear.
  6. Rotate the differential side gears until the pinion gears is directly opposite the opening in the differential case.

    7. Note: Rotate the pinion gears toward the differential opening in order to permit the sliding in of the thrust washers.

  7. Install the thrust washers.
  8. Install the pinion shaft.

    9. Caution: Refer to Fastener Caution in the Preface section.

  9. Install and tighten new pinion shaft lock bolt to 25 N·m (18 lb ft)..

    10. Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.


    Object Number: 866505 Size: SH
  10. Install the ring gear to the differential case.

    11. Object Number: 866503 Size: SH

    Note: 

       • The ring gear bolts have left-hand threads.
       •  Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

  11. Install the new ring gear bolts.

    12. Note: tightening the ring gear bolts in sequence, will seat the ring gear evenly on the differential case.

  12. Tighten the ring gear bolts in sequence to 130 N·m (96 lb ft).
  13. Install the differential side bearings. Refer to Differential Side Bearings Replacement.