Vauxhall Workshop Service and Repair Manuals

  Remove

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

  Install

To fasten Bracket KM-622-A (2) to rear differential, thread (M12) must be cut at mounting points (1), or – if threaded – cleaned or recut.

Attach differential to assembly stand or workbench with KM-622-A and KM-113-2 (3). Unbolt differential cover and allow fluid to run out in collecting basin.

  Disassemble

Unscrew bracket for front damping bushing (1) (3 fastening bolts). Prise out both seal rings for drive shafts with a tyre lever.

Secure KM-621-20 (2) and KM-621-8 (3) on transmission casing. Insert KM-621-8 such that retaining rings can be disassembled.

Compress differential with KM-621-20 and KM-621-8 so far until retaining ring for bearing ring can move freely. Remove retaining ring (4). Remove KM-621-20 and KM-621-8. Remove retaining ring for other bearing ring.

Drive bearing ring of differential from differential housing with light blows (arrow) with brass drift on shoulder of bearing outer ring. Remove differential with ring gear out of differential housing. Remove other bearing ring from differential housing. Remove O-ring from bearing ring.

Unscrew fastening nut of differential flange (hex socket A/F 30 mm, long version). Use KM-623 (1) to counterhold.

Remove flange from drive bevel gear using KM-628-A (2). Counterhold with wrench (A/F 41 mm) on KM-628-A (2).

Lever out seal ring (1) with tyre lever.

Press drive bevel gear out of rear axle housing and to do this place a piece of wood (2) under the drive bevel gear so that no damage is incurred if it should impact with anything. Take out drive bevel gear and outer bearing inner race.

Press out outer race of outer drive bevel gear bearing using KM-305 (3) in conjunction with KM-621-9 (4) and KM-621-16 (5).

Press out outer ring of inner drive pinion bearing with KM-305 (1), see illustration on the right.

Remove tension sleeve (2) from drive pinion.

Press off inner tapered roller bearing of drive pinion:

For design (I) use drive pinion with collar - KM-501 (1).

For design (II) use drive pinion with collar, estate and 6 cylinder engines - KM-621-13 (2) in conjunction with KM-621-14 (3).

For design (III) use drive pinion without collar - KM-6118-1 (4) from KM-6118 in conjunction with KM-6393 (5).

  Assemble

Assemble differential – see operation for "Assemble Differential".