Vauxhall Workshop Service and Repair Manuals

Differential, Assemble and Install (Transmission Removed)

Apply a coat of Transmission Fluid 19 40 750 (90 001 777) to sliding surfaces of pinion shaft, pinions and plate washers prior to installation.

Install side gears and differential pinions, plate washers and pinion shaft in differential housing.

Pre-assemble differential pinions and plate washers with KM - 456.

Screw side gears with plate washers into differential housing.

Insert new retaining rings with Gripper 12 (commercially available).

Bolt ring gear onto differential case and tighten 85 Nm/63 lbf. ft.

Preheat drive gear to 80 °C/176 °F (use thermocolour pencils or suitable temperature gauge).

Use new hex bolts.

Always replace the ring gear and main shaft gear as a pair.

- Note groove mark (grooves running around tip of tooth).

Use KM - 459 to drive new speedometer helical gear (driving) onto the differential housing until it snaps into place.

Preheat speedometer gear and KM - 459 in a water bath to approx. 80 °C/176 °F.

Clamp differential housing in vise using KM - 458 - A.

The cams of the gear must be positioned above the recesses in the differential case.

Apply a coat of Antifriction Bearing Grease 19 41 574 (90 001 812) to the splines of the helical gear.

Press both tapered roller bearing inner races onto differential housing using KM-453 (2 parts).

Press tapered roller bearing outer race into the transmission housing and bearing ring using KM - 304 and KM - 451 (with transmission housing removed).

With transmission housing installed, draw bearing outer race into transmission housing using KM - 120 - 2 and - 3 and KM - 451.

To do this, lightly tap the bearing outer race in the transmission housing.

Use KM - 446 to drive both seals for the axle shafts flush into the bearing rings and transmission housing.

The dust seal lip points outward.

Coat seal lips with Protective Grease 19 48 524 (90 001 825).

Insert differential into transmission housing.

Use KM - 447 to screw bearing ring into case.

Apply Protective Grease 19 48 524 (90 001 825) to the threads of the bearing ring as well as to the rubber O-rings (these points must be oil-tight).