Vauxhall Workshop Service and Repair Manuals

  Remove

Remove differential – refer to operation "Remove and Install or Replace Differential". Secure differential with KM-622-A (1) in conjunction with KM-113-2 (2) to assembly frame or workbench.

Caution

Increase distance of KM-622 to differential reinforcement rib by welding on washers approx. 5 mm thick (3). After modifying, change tool number by adding "-A" to make KM-622-A.

  Measure

Measure and record slip torque of rear differential with MKM-536-A (4) and KM-885 (5) before beginning repair work.

  Remove

Unbolt hex nut for drive flange, counterholding with KM-623 (6).

Remove drive flange from drive bevel gear using KM-628-A (1). Lever seal ring (2) out of rear differential housing, ensuring that seating surfaces on rear axle housing do not get damaged.

  Install

To prevent damage to the new seal, increase (II) of KM-629-1 to II = 6 mm. When doing this, diameter I = 63 mm must not change. Following the modification, change the tool number by attaching an -A (making it KM-629-1-A).

When replacing the seal, also install the modified flange with new O-ring to obtain a better seal.

Caution

Before installation coat new seal ring at the sealing lips with special fluid. Drive seal ring flush into rear differential housing with KM-629-1-A (1). Place flange onto drive pinion gear and tighten further with hex nut (counterhold with KM-623 (2)) – in doing so, check bearing pre-tension continuously with MKM-536-A (3) and KM-885 (4).

Adjust slip torque to previously measured value.

Caution

If pre-tension is exceeded, loosen drive pinion nut and repeat measurement.

  Install

Install rear differential, see operation "Rear Differential, Remove and Install or Replace".

Check fluid level of rear differential and correct – see operation "Fluid Level, Check and Correct".