GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 RELAY 🢒 General Information 🢒 General Information 🢒 Differential Replacement

Removal Procedure
  1. Set the parking brake.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Remove the right rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  4. Place a drain pan beneath the differential.

    5. Object Number: 690489 Size: SH
  5. Remove the differential drain plug (2).
  6. Drain the rear differential gear oil.
  7. Disconnect the electrical connector from the clutch pump check valve.
  8. Remove the right rear wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
  9. Remove the front propeller shaft. Refer to Propeller Shaft Replacement .
  10. Place an adjustable support beneath the torque tube.

    11. Object Number: 630649 Size: SH
  11. Loosen, but do not remove the torque tube-to-bracket through bolt (7) and nut (1).
  12. Remove the bolts (5) from the torque tube bracket  (4).

    13. Object Number: 690531 Size: SH
  13. Remove the differential carrier-to-cradle mounting bolts (5), nuts (1), washers (2), and mounts (3, 4) from the differential.

    14. Important: During the removal of the wheel drive shaft, the differential output shaft may become disengaged from the differential. If this occurs, firmly grasp and separate the output shaft from the wheel drive shaft. Align the splines on the output shaft to the differential and reposition the output shaft to the differential.

  14. While simultaneously moving the differential assembly to the right side of the vehicle, disengage the left wheel drive shaft from the differential.
  15. Remove the rear differential and torque tube as an assembly.

    16. Object Number: 630652 Size: SH
  16. Remove the torque tube (1) from the differential (2). Refer to Driveline Torque Tube Replacement .

Installation Procedure

    Object Number: 630652 Size: SH
  1. Install the torque tube (1) to the differential. Refer to Driveline Torque Tube Replacement .
  2. Install the rear differential and torque tube assembly to the suspension cradle.

    3. 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.

    5. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 690531 Size: SH
  5. Install the differential carrier mounts (3, 4), washers (2), bolts (5), and nuts (1) to the differential.

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


    Object Number: 630649 Size: SH
  6. Install the torque tube bracket-to-body bolts (5).

    7. 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 Rear Wheel Drive Shaft Replacement .
  9. Install the right rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

    10. Object Number: 690489 Size: SH
  10. Install the differential drain plug (2) and gasket to the differential.

    11. 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 Axle 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) and gasket.

    15. 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.