differential CHEVROLET AVEO 2002 Service Owner's Manual

Fig. 401: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
7. Remove the differential pinion shaft from the case.

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Fig. 402: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side
Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
8. Remove the 2 differential pinion gears, 2 differential side gears, 2 differential pinion thrust washers, and
2 differential side gear thrust washers.

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Fig. 406: Removing Transaxle Case Side Bearing Outer Race & Shim Using DT 46463 & DT 46465
Courtesy of GENERAL MOTORS CORP.
12. Using the DT 46463 (2) and the DT 46465 (1), remove the transaxle case side bearing outer race and
shim. See Special Tools
.
DIFFERENTIAL ASSEMBLY ASSEMBLE
Tools Required
DT 46462 (DW240-140) Transaxle Case Side Bearing Outer Race Adapter. See Special Tools.
DT 46465 (DW240-170) Adapter Handle. See Special Tools.
DT 46461 (DW240-130) Differential Preload Adapter. See Special Tools.
DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer. See Special Tools.
DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer. See Special Tools.

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Fig. 409: Differential Side Gear Thrust Washers & Differential Side Gears
Courtesy of GENERAL MOTORS CORP.
4. Coat the thrust washers, side gears, pinion gears, and pinion thrust washers with automatic transmission
fluid (ATF).
5. Install the 2 differential side
gear thrust washers to 2 differential side gears.

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Fig. 410: Differential Side Gears, 2 Differential Pinion Thrust Washers, And 2 Differential Side
Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
6. Install the 2 side gears with 2 thrust washers, 2 pinion gears, and 2 pinion thrust washers into the
differential case.
7. Coat the pinion shaft with ATF.

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Fig. 411: Differential Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
8. Install the pinion shaft so as to ali
gn the lock pin holes on the pinion shaft and differential case.

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Courtesy of GENERAL MOTORS CORP.
11. Using a hammer and punch, drive in the pin through the case and holes in the pinion shaft.
Fig. 414: Staking The Differential Case Using A Hammer & Chisel

Courtesy of GENERAL MOTORS CORP.
12. Usin
g a hammer and chisel, stake the differential case.

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Fig. 415: Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
13. Using a press, install the tapered roller bearing into the differential case.

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Fig. 416: FIPG, Tapered Roller Bearing & Differential Case
Courtesy of GENERAL MOTORS CORP.
14. Using a press, install the tapered roller bearing into the differential case.
15. Remove any formed in place gasket (FIPG) material. Do not get oil on the contacting surfaces of the
transaxle housin
g or transaxle case.

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Fig. 417: Differential & Transaxle Case
Courtesy of GENERAL MOTORS CORP.
16. Install the differential to the transaxle case.

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