Vauxhall Workshop Service and Repair Manuals

Overhaul differential gear up from model year 2007,5 (F17+)

Note:   Transmission remains installed.

  Remove

1.   Detach axle shafts (1) from transmission Note:   Axle shafts remain in wheel hub. 2.   Remove end shield cover (2) . 3.   Remove end shield (3) 4.   Remove differential (4)

5.   Remove 2x axle shaft sealing rings from bearing ring (3) and transmission •   Remove axle shaft seal ring with KM-454-2 (1) and KM-454-4 (2) 6.   Remove tapered roller bearing outer race from bearing ring Note:   Only necessary when replacing bearing in bearing ring. •   Place outer race of tapered roller bearing with KM-303 (6) •   Remove tapered roller bearing outer race from transmission with KM-304 (4) and KM-451 (5) 7.   Remove tapered roller bearing outer race from transmission Note:   Only necessary when replacing bearing in transmission. •   Remove tapered roller bearing outer race from transmission with KM-305 and KM-451 Note:   If the transmission has been removed, use KM-304 and KM-451 .

8.   Detach 2x tapered roller bearing inner ring (1) from differential gear Note:   Only necessary when replacing. Do not interchange outer and inner races respectively when re-using tapered roller bearings. •   Pull off tapered roller bearing inner ring with KM-161-B (4), KM-161-3 (3) and KM-161-4 (2) 9.   Detach ring gear from differential housing •   Clamp differential housing in vice Note:   Use protective jaws. •   Unscrew 8x bolt (5)

10.   Separate ring gear (1) from differential housing with plastic hammer Note:   Note peripheral groove marking (arrows) on gear head. •   Clamp ring gear in vice Note:   Use protective jaws. 11.   Dismantle differential housing (3) •   Clamp differential housing in vice Note:   Use protective jaws. •   Drive lock pin (4) into bevel gear shaft (5) using suitable drift (2) up to the stop. •   Remove bevel gear shaft from differential housing •   Remove axle shaft and differential bevel gears with KM-458-A •   Remove plastic cage

  Install

14.   Drive locking pin (1) out of bevel gear shaft (2) •   Clamp bevel gear shaft in vice Note:   Use protective jaws. •   drive out with suitable drift

Important:   Lubricate bearing, running, seating, and pressure surfaces of rotating parts with transmission fluid. 15.   Insert plastic cage in differential gear Note:   It must be possible to insert collar (1) of plastic cage into guide for axle shaft bevel gears in housing. 16.   Assemble differential housing •   Clamp differential housing in vice Note:   Use protective jaws. •   Insert axle drive and differential bevel gears (3) into differential housing •   Use 2x KM-458-A (2) to screw in differential bevel gears

17.   Install bevel gear axis (4) •   Drive new lock pin into bevel gear shaft using suitable drift (1) Note:   Drive pin (3) flush into differential housing (2)

18.   Attach ring gear (1) to differential housing Note:   Replace drive gears only in pairs (driving and driven). Note identification groove (arrows) running around tip of tooth. •   Clean 8x threads •   Tighten 8x new bolts evenly 70 Nm + (30° - 45°) Note:   Insert bolts with locking compound

19.   Attach 2x tapered roller bearing inner races (2) •   Press 2x inner races of tapered roller bearings onto differential housing (3) using KM-453 (1)

20.   Attach 2x tapered roller bearing outer races •   Install tapered roller bearing outer race (2) into transmission and/or bearing ring with KM-304 (1) and KM-451 (3) 21.   Fit axle shaft seal rings •   Install axle shaft seal rings into bearing ring and transmission housing with KM-446 22.   Install differential (4)

23.   Install end shield (2) 24.   Attach end shield cover (1)

26.	Check transmission fluid level