Differential Replacement. Pontiac Sun Runner - 4WD (Canada) 1998

For 1990-2009 cars

### Removal Procedure

1. Raise the vehicle. Support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Place a drain pan or suitable container under the rear axle housing.
3. Remove the rear axle housing oil level/filler plug (1) from the rear axle housing.
4. Remove the rear axle housing drain plug (2) from the rear axle housing.
5. Drain the rear axle housing.
6. Remove the rear tire and wheel assemblies. Refer to Wheel Removal in Tires and Wheels.
7. Remove the rear brake drums from the rear axle. Refer to Brake Drum Replacement in Drum Brakes.

Important: To ensure rear propeller shaft balance, an index mark (reference mark) (1) must be placed on the differential pinion flange and the rear propeller shaft flange so that the rear propeller shaft (2) can be installed in the same position from which it was removed. If this procedure is not followed, a driveline imbalance may result causing vibration, premature component wear or other undesirable characteristics.

8. Remove both rear axle shafts from the rear axle housing. Refer to Axle Shaft Replacement .
9. Remove the following from the vehicle:

• | The four bolts

• | The four nuts

• | The rear propeller shaft (2)

10. Loosen both rear control arm through bolts and nuts.
11. If the vehicle is LSPV equipped, remove the two bolts securing the Load Sensing Proportioning Valve (LSPV) spring bracket to the upper control arm.
12. Remove the four bolts from the rear control arm ball joint boss (3). Separate the rear control arm ball joint boss from the differential carrier.
13. If vehicle equipped, remove the two bolts and the rear wheel speed sensor cover (1) from the differential carrier (2).
14. If vehicle equipped, remove the electrical connector (1) from the rear wheel speed sensor.
15. Remove the eight nuts and the differential carrier (2) from the rear axle housing (1).
16. Clean the oil and sealant from the differential carrier and the rear axle housing mating surfaces.
17. Inspect the differential carrier.

### Installation Procedure

1. Apply RTV silicone gasket and sealer GM P/N 12346240, or equivalent, to the differential carrier mating surface (1) on the rear axle housing (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.

2. Install the differential carrier into the rear axle housing. Secure the differential carrier with eight nuts (1).

Tighten
Tighten the differential carrier nuts to 55 N·m (41 lb ft).

3. If vehicle equipped, install the electrical connector (1) to the rear wheel speed sensor.
4. If vehicle equipped, install the rear wheel speed sensor cover (1) to the differential carrier (2). Secure the cover with two bolts.

Tighten
Tighten the rear wheel speed sensor cover bolts to 15 N·m (11 lb ft).

5. Install the rear control arm ball joint boss (3) to the differential carrier (2). Secure ball joint boss with four bolts.

Tighten

• | Tighten the rear control arm ball joint boss bolts to 50 N·m (37 lb ft).

• | Tighten the rear control arm through bolts and nuts to 90 N·m (66 lb ft).

Important: Use the index (reference) marks made in the removal procedure to ensure correct rear propeller shaft installation.

6. If vehicle equipped, install the LSPV load sensing spring bracket to the upper control arm. Secure the bracket with two bolts.

Tighten
Tighten the load sensing spring bracket bolts to 18 to 25 N·m (13.5 to 20.0 lb ft).

7. Install the rear propeller shaft (2) into the vehicle. Secure with four nuts and bolts.

Tighten
Tighten the rear propeller shaft nuts and bolts to 50 N·m (37 lb ft).

8. Install both rear axle shafts into the rear axle housing. Refer to Axle Shaft Replacement in this section.
9. Install the rear brake drums to the rear axle. Refer to Brake Drum Replacement in Drum Brakes.
10. Install the rear tire and wheel assemblies. Refer to Wheel Installation in Tires and Wheels.
11. Apply GM P/N 12346004, or equivalent, to the threaded portion of the rear axle housing drain plug.
12. Install the rear axle housing drain plug (2) into the rear axle housing.

Tighten
Tighten the rear axle housing drain plug to 25 N·m (18 lb ft).

13. Refill the rear axle housing with approximately 2.2 liters (4.6 pts) of 80W-90 GL5 lubricant GM P/N 12345977, or equivalent. The oil level should be even with the bottom of the rear axle housing oil level/filler plug hole.
14. Install the rear axle housing oil level/filler plug (1) into the rear axle housing.

Tighten
Tighten the rear axle housing oil level/filler plug to 43 N·m (32 lb ft).

15. Remove the drain pan from under the rear axle housing.
16. Lower the vehicle.