Front Drive Axle: Overhaul Cadillac STS I

Differential Carrier Assembly - Disassemble

Tools Required

1. J 22912-01 Split-Plate Bearing Puller
2. J 25070 Heat Gun
3. J 29873 Injector Nozzle Socket 30 mm. See «Special Tools»(ref-197620-S22095717962005101200000) .
4. J 45012 Pinion Flange Holder. See «Special Tools»(ref-197620-S22095717962005101200000) .
5. J 45019 Flange and Pinion Cage Remover. See «Special Tools»(ref-197620-S22095717962005101200000) .
6. J 45114 Bearing Cup Remover (F4WD). See «Special Tools»(ref-197620-S22095717962005101200000) .
7. J 45124 Removal Bridge. See «Special Tools»(ref-197620-S22095717962005101200000) .

1. Remove the bolts (10) from the pinion bearing housing (3).
2. Install the J 45019 and slide hammer as shown. See «Special Tools»(ref-197620-S22095717962005101200000) .
3. Using the J 25070 , heat around the pinion housing in order to ease removal.
4. Remove the J 45019 from the flange. See «Special Tools»(ref-197620-S22095717962005101200000) .
5. Remove the pinion housing from the differential carrier.
6. Remove the O-ring from the housing.
7. Remove the pinion housing shims.
8. Remove the carrier cover bolts.
9. Using the pry tabs, remove the carrier cover.
10. Remove the O-ring from the cover.
11. Remove the differential assembly from the carrier.
12. Remove the axle oil seal from the cover.
13. Install J 45114 into the bearing cup. See «Special Tools»(ref-197620-S22095717962005101200000) .
14. Tighten the spreader bolt in order to lock the tool into the cup.
15. Place J 45124 (1) over J 45114 (2) with the center bolt. See «Special Tools»(ref-197620-S22095717962005101200000) .
16. Tighten the center bolt and remove the cup and shim. Mark or tag the shim and cup if they will be reused.
17. Using a suitable tool, remove the stub shaft oil seal from the carrier.
18. Install J 45114 (2) into the bearing cup. See «Special Tools»(ref-197620-S22095717962005101200000) .
19. Place J 45124 (1) over J 45114 (2) with the center bolt. See «Special Tools»(ref-197620-S22095717962005101200000) .
20. Tighten the center bolt and remove the cup and shim. Mark or tag the shim and cup if they will be reused.
21. Remove the ring gear bolts and discard.
22. Using a punch, remove the ring gear by driving the gear off from several holes.
23. Remove the differential shaft from the differential case by pushing it out.
24. Rotate the axle side gears (107) to spin out the pinion gears (109) and thrust washers (106, 108) from the differential case (104).
25. Remove the axle side gears (107) and thrust washers from the differential case.
26. Using J 22912-01 and a press, remove the left side differential bearing. Remove the cage and rollers in order to get a grip on the inner bearing race.
27. Using J 22912-01 and a press, remove the right side differential bearing. Remove the cage and rollers in order to get a grip on the bearing.
28. In order to secure the flange, attach the J 45012 to the pinion flange using 2 bolts and washers from J 45019 . See «Special Tools»(ref-197620-S22095717962005101200000) .
29. Place a 1/2-inch breaker bar in the square end of the J 45012 (2). See «Special Tools»(ref-197620-S22095717962005101200000) .
30. Using J 29873 (1), remove the pinion nut. See «Special Tools»(ref-197620-S22095717962005101200000) .
31. Remove the pinion flange from the shaft using J 45019 with forcing screw, bolts and washers. See «Special Tools»(ref-197620-S22095717962005101200000) .
32. Place the pinion housing in a press. Press the pinion drive gear from the housing.
33. Remove the spacer from the drive pinion shaft.
34. Install J 22912-01 under the pinion shaft head bearing inner race.
35. Place the drive pinion shaft in a press and remove the bearing from the shaft.
36. Remove the pinion oil seal and the pinion shaft tail bearing from the pinion housing.

Differential Carrier Assembly - Assemble

Tools Required

1. J 8092 Universal Driver Handle
2. J 24433 Pinion Cone and Side Bearing Installer. See «Special Tools»(ref-197620-S22095717962005101200000) .
3. J 25070 Heat Gun
4. J 29873 Injector Nozzle Socket 30 mm. See «Special Tools»(ref-197620-S22095717962005101200000) .
5. J 45012 Pinion Flange Holder. See «Special Tools»(ref-197620-S22095717962005101200000) .
6. J 45017 Output Shaft Seal Installer. See «Special Tools»(ref-197620-S22095717962005101200000) .
7. J 45019 Flange and Pinion Cage Remover. See «Special Tools»(ref-197620-S22095717962005101200000) .
8. J 46262 Pinion Sealer. See «Special Tools»(ref-197620-S22095717962005101200000) .
9. J 46265 Stub Shaft Seal Installer. See «Special Tools»(ref-197620-S22095717962005101200000) .

1. Install the axle side gears (107) and washers (106) into the differential carrier (104).
2. Install the washers (108) on the pinion gears (109).
3. Install the pinion gears into the differential carrier (104) across from each other.
4. Use the differential shaft (103) to align the gears.
5. Rotate aligned gears slowly until holes in the differential case (104) and the pinion gears (109) align with each other. Install the differential shaft (103).
6. Install the bolts that have the heads removed guide into the gear bolt holes.
7. Using a press and J 24433 , press the ring gear (105) on the differential. See «Special Tools»(ref-197620-S22095717962005101200000) .
8. Remove the guide pins.
9. Install NEW ring gear bolts. Tighten: Tighten the ring gear bolts to 67 N.m (49 lb ft) in a criss-cross pattern.
10. Install the pinion head bearing (14) onto the drive pinion gear (111) using J 24433 and a hydraulic press. See «Special Tools»(ref-197620-S22095717962005101200000) .
11. Assemble the drive pinion shaft (111) and pinion bearing spacer (12) through the pinion bearing housing (3) with the tail bearing (7) over the pinion shaft.
12. Press the bearing onto the pinion shaft using J 24433 and a hydraulic press. See «Special Tools»(ref-197620-S22095717962005101200000) .
13. Using J 46262 , install a NEW pinion seal. See «Special Tools»(ref-197620-S22095717962005101200000) .
14. Install the pinion flange (5) onto the shaft.
15. Install a NEW pinion nut (4).
16. Install J 45012 (2) in order to hold the flange with a breaker bar. See «Special Tools»(ref-197620-S22095717962005101200000) . Tighten the pinion flange nut with a torque wrench and J 29873 (1). See «Special Tools»(ref-197620-S22095717962005101200000) . Tighten: Tighten the pinion flange nut to 241 N.m (178 lb ft).
17. Using J 46265 (2) and J 8092 (1), install the stub shaft seal. See «Special Tools»(ref-197620-S22095717962005101200000) .
18. Install the selected shims (9) on the pinion housing (3).
19. Install the O-ring (11) in the groove on the pinion housing.
20. Apply a light coat of gear lube to the bearing housing to ease installation.
21. Apply a light coat of gear lube into the pinion housing bore of the carrier.
22. Using J 25070 , heat the carrier.
23. Using the long bolts from J 45019 as guides, align the housing bolt holes to the carrier bolt holes. See «Special Tools»(ref-197620-S22095717962005101200000) .
24. Snug the bolts.
25. Push the housing evenly into the bore.
26. Remove the long bolts.
27. Install the pinion housing bolts. Tighten: Tighten the bolts to 29 N.m (21 lb ft).
28. Install the differential assembly (100) into the differential carrier (1).
29. Lightly lube the outside diameter of the oil seal with axle lube.
30. Use J 45017 to install the oil seal (21). See «Special Tools»(ref-197620-S22095717962005101200000) .
31. Install the carrier cover O-ring into the groove.
32. Apply a light coat of gear lube to the O-ring area.
33. Align the bolt holes and push cover onto the differential carrier evenly.
34. Start the cover bolts in the holes by hand.
35. Install the cover bolts. Tighten: Tighten the cover bolts to 29 N.m (21 lb ft) in a criss-cross pattern.
36. Install the drain plug. Tighten: Tighten the drain plug to 39 N.m (29 lb ft).
37. After the axle and half shaft is installed in the vehicle, fill the axle with differential lube GL 75W90 GM P/N 12378261 (Canadian P/N 10953455) or equivalent. Fill to the bottom of the fill plug threads.
38. Install the fill plug (23). Tighten: Tighten the fill plug to 39 N.m (29 lb ft).