Chevrolet Sonic Repair Manual: Differential Case Assemble

Special Tools

• J-810721 Axle Shaft Seal Remover Support Base
• R-0407011 Bearing Race Remover
• R-0407012 Differential Carrier Cone Bearing Cap Driver
• R-0007761 Universal Handle for Pullers and Installers
• S-9407194 Speed Sensor Impeller Ring Installer
• S-9407195 Pinion Gear Case Bearing Installer
• S-9707500 Seal Installer

For equivalent regional tools, refer to Special Tools.

1. Install the front differential pinion and side gear thrust washer. It must be possible to insert the collar (1) of the thrust washer into the guide for the pinion gears in the housing.



Note:

Lubricate rotating parts on their bearing, running, seating, and pressure surfaces using transmission fluid.

2. Install the front differential pinion gears (3) and side gears (4).
3. Install the front differential pinion gear shaft (2) and the pinion gear shaft retaining washers (1).


4. If both components are reused align the assembly marks (3).
5. Install the front differential ring gear (2).

Warning:

Refer to Safety Glasses Warning.

6. Install the front differential ring gear bolts (1). Tighten to 90 N•m (66.4 lb ft)

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7. Install the ring front wheel speed sensor reluctor wheel (1) using the S-9407194 installer and a hydraulic press.



8. Install the front differential bearing assemblies (1) using the S-9407195 installer and a hydraulic press.



9. Install the front wheel drive shaft oil seal (3) using the R-0007761 handle  (1), S-9707500 seal installer  (2), and the J-810721 support base  (4).



10. Install the front differential bearing race (3) using the R-0007761 handle  (1) and the R-0407012 driver  (2).

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