2008 PONTIAC SOLSTICE Service Repair Manual

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Propeller Shaft | Specifications |
Document ID: 1868126
Fastener Tightening Specifications
Application
Specification
Metric English
Driveline Support Bracket Bolts at Differential 80 N·m 59 lb ft
Driveline Support Bracket Bolts at Transmission 185 N·m 136 lb ft
Driveline Support at Differential 200 N·m 148 lb ft
Propeller Shaft C/V Flange Bolts - Front 40 N·m 30 lb ft
Rear Differential Mounting Bolt 175 N·m 129 lb ft
Rubber Couplings to Flanges - Rear 85 N·m 63 lb ft
© 2010 General Motors Corporation. All rights reserved.
Page 1 of 1Document ID: 1868126
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2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Propeller Shaft | Specifications |
Adhesives, Fluids, Lubricants, and Sealers
Application Type of Material
GM Part Number
United States Canada
Propeller Shaft Centering Bushings Lubricant 1051344 993037
Propeller Shaft-to-Flange Bolts Threadlocker 12345493 10953488

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Propeller Shaft | Repair Instructions |
Propeller Shaft, Differential, and Driveline Support
Replacement
Special Tools
J 44394 Axle Seal Protector
Removal Procedure
1. Remove the left rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement.
2. Remove the muffler and exhaust pipe. Refer to Exhaust Muffler Replacement.
3. Remove the floor panel tunnel panel front closeout panel. Refer to Floor Panel Tunnel Panel
Replacement - Front.
4. Remove the floor panel tunnel rear panel. Refer to Floor Panel Tunnel Panel Replacement -
Rear.
5. Support the transmission with a suitable jack stand.
6. Loosen, but DO NOT remove the driveline support to the transmission bolts (1).
7. Remove the transmission close out panel. Refer to Transmission Support Replacement.
8. Loosen, but DO NOT remove the left and right motor mount bolts.
• For vehicles equipped with the 2.0L, refer to Engine Mount Replacement - Left Side and
Engine Mount Replacement - Right Side.
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9. Remove the front propeller shaft bolts (1) and washer support tabs (2) from the
transmission.
10. Support the rear differential with a transmission jack stand.

Note: The proper nuts and bolts to be removed are those where the nut is the closest or
facing the rear differential drive flange. DO NOT remove the nuts and bolt where the nuts are
facing the front or propeller shaft.
11. Remove the propeller shaft nuts and bolts from the rear differential.
12. Remove the left (1) and right (2) rear differential mount bolts.
13. Lower the rear differential enough to clear the rear crossmember.
14. Install the J 44394 protector and move the rear differential to the left side of the vehicle to
remove the right rear wheel drive shaft.

Note: DO NOT re-use the bolts, discard and use NEW only.
15. Remove the four differential carrier bracket bolts (1).
16. Separate the differential carrier (1) from the driveline support bracket (2).

17. Remove the propeller shaft from the vehicle.
Note: Steps 18 and 19 are for the replacing the driveline support.
18. Remove the driveline support bolts (1) and the washers (2) from the transmission.

19. Remove the driveline support (1) from the transmission and the rear differential assembly.
20. If servicing the driveline support, remove the nut (1), bolt (2), and the washer block (3) from
the driveline support.
21. Remove the driveline support (4) from the rear differential assembly.

Note: Support the right rear wheel drive shaft with mechanics wire.
22. If servicing the rear differential assembly, remove the rear differential assembly from the
vehicle.
Installation Procedure
1. Clean the bolt holes in the differential carrier with brake cleaner or other suitable solvents to
remove any adhesive.
2. If servicing the driveline support, position the driveline support (4) on the differential
housing.
3. Install the bolt plate (3), bolts (2) for the driveline support on the differential housing.

Caution: Refer to Component Fastener Tightening Caution in the Preface section.
4. Install the nuts (1) for the drive line support bolts (2) and tighten to 200 N·m (148 lb ft).
5. Position the driveline support (1) on the transmission.
Note: Leave the driveline support bolts loose.
6. Install the driveline support bolts (1) and washers (2).

7. Raise the differential to just below the rear crossmember.
8. Clean the pilot shaft (1) and the pilot hole (2) of any dirt or debris.
9. Apply a small amount of chassis lube on the pilot shaft (1).
10. Align the pilot shaft (1) and the pilot hole (2).

11. Install the propeller shaft to the transmission and differential.
Note: In steps 11 and 12, finger tighten the front and rear propeller shaft nuts and bolts
only. DO NOT torque the propeller shaft nuts and bolts until the differential and driveline
support have been aligned and torqued to specifications.
12. Install the propeller shaft bolts (1) and washer support tabs (2) in the transmission drive
flange.

Note: Ensure that the driveline support bracket and the differential are properly joined.
13. Align the differential carrier (1) and the torque beam bracket (2).
14. Apply GM threadlocker to the NEW differential carrier bracket bolts (1). Refer to Adhesives,
Fluids, Lubricants, and Sealers.
Note: Use only hands tools to tighten the driveline support bolts.
15. Install the four new driveline support bracket bolts (1) and tighten to 80 N·m (59 lb ft).
16. Raise and position the differential in the rear support.

Note: Install the left and right rear differential bolts by hand before tightening to
specifications.
17. Install the left (1) and right (2) rear differential bolt and tighten to 175 N·m (129 lb ft).
18. Tighten the rear propeller shaft bolts to 85 N·m (63 lb ft).
19. Tighten the front propeller shaft bolts in sequence (1-6) to 40 N·m (30 lb ft).
20. Install the left rear wheel drive shaft. Refer to Wheel Drive Shaft Replacement.

Note: Failing to perform the following service procedure will create the wrong driveline angle
for the propeller shaft and alignment of the transmission and the rear differential.
21. Position a scale or known straight edge across the floor pan where the driveline tunnel
closeout mounts to the body.
22. Position another scale at the transmission output shaft oil seal slinger.
23. Using the jack stand, raise or lower the transmission until a measurement of 80 mm
(3.150 inch) is obtained.
24. Tighten the driveline support bolts (1) at the transmission to 185 N·m (136 lb ft).
25. Remove the jack stand from the rear differential.
26. Tighten the left and right motor mount bolts.

27. Remove the transmission jack stand.
28. Install the transmission close out panel. Refer to Transmission Support Replacement.
29. Install the floor panel tunnel panel front closeout panel. Refer to Floor Panel Tunnel Panel
Replacement - Front.
30. Install the floor panel tunnel rear panel. Refer to Floor Panel Tunnel Panel Replacement -
Rear.
31. Install the muffler and exhaust pipe from the vehicle. Refer to Exhaust Muffler Replacement.

Propeller Shaft Replacement (Automatic)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the exhaust pipe and muffler. Refer to Muffler Replacement.
3. Remove the floor panel rear panel. Refer to Floor Panel Tunnel Panel Replacement - Rear.
4. Support the rear differential assembly with a suitable jack stand.
5. Remove the left (1) and right (2) rear differential support bolts.
6. Remove the front differential support bolt (1).

7. Remove the propeller shaft bolts from the transmission output flange.
8. Remove the propeller shaft nut and bolts from the differential drive flange.
9. Lower the rear differential assembly enough to remove the propeller shaft from the vehicle.
1. Remove all debris from the pilot shaft.
2. Apply a small amount of chassis lube on the pilot shaft and pilot shaft hole in the propeller
shaft.
3. Position the propeller shaft on the transmission output flange.
4. Raise the rear differential at the same time as aligning the propeller shaft pilot shaft and the
propeller shaft pilot hole.

Note: DO NOT tighten the propeller shaft front or rear fasteners until the front and rear
differential support bolts are tighten to specifications.
5. Hand tighten the propeller shaft bolts to the transmission output shaft flange.
6. Hand tighten the nuts and bolts to the rear differential drive flange.
7. Position the rear differential assembly in the support.
Caution: Refer to Fastener Caution in the Preface section.

8. Install the left (1) and right (2) rear differential support bolts and tighten to 175 N·m
(129 lb ft).
9. Install the front differential support bolt (1) and tighten to 175 N·m (129 lb ft).
10. Remove the jack stand from the rear differential assembly.

11. Tighten the front propeller shaft bolts in sequence 1-6 to 40 N·m (30 lb ft).
12. Tighten the rear propeller shaft bolts and tighten to 85 N·m (63 lb ft).
13. Install the floor panel rear panel. Refer to Floor Panel Tunnel Panel Replacement - Rear.
14. Install the exhaust pipe and muffler. Refer to Muffler Replacement.
15. Remove the support and lower the vehicle.

Propeller Shaft Replacement (RPO ZOK)
Callout Component Name
Preliminary Procedures
1. Remove the floor panel tunnel rear panel. Refer to Floor Panel Tunnel Panel
Replacement - Rear.
2. Support the rear drive module (RDM).
3. Remove the bolt from the differential case bracket assembly to body.
1
Propeller Shaft Coupling Nut (Qty: 3)
Tip
Tighten
85 N·m (63 lb ft)
• DO NOT remove the bolts from the coupler to the propeller shaft. Remove
only the bolts from the coupler to the drive axle pinion flange.
• Clean the threads and apply LOCTITE. Refer to Adhesives, Fluids, Lubricants,
and Sealers.
2 Propeller Shaft Coupler Bolt (Qty: 3)

3
CV Joint Mounting Bolt (Qty: 6)
Tip
Tighten
40 N·m (30 lb ft)
• The CV joint mounting bolts MUST be tightened in a star pattern sequence.
• Clean the threads and apply LOCTITE. Refer to Adhesives, Fluids, Lubricants,
and Sealers.
4 CV Joint Mounting Bolt Spacer
5
Propeller Shaft
Tip
• Before installation, apply a small amount of lubricant to the front and rear
propeller shaft center bushings. Refer to Adhesives, Fluids, Lubricants, and
Sealers.
• Lower the front of the RDM to remove the propeller shaft from the pinion
flange.

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Rear Drive Axle | Specifications |
Application
Specification
Metric English
Differential Carrier Bracket to Bracket Reinforcement Bolt
(Automatic only)
175 N·m 129 lb ft
Differential Carrier Bracket Reinforcement (Automatic only) 110 N·m + 20 degrees --
Driveline Support to Driveline Support Bracket Bolts
(Manual Only)
200 N·m 148 lb ft
Driveline Support Bracket to Differential Bolts 80 N·m 59 lb ft
Differential Carrier Cover Bolts 25 N·m 18 lb ft
Differential Ring Gear Bolts 185 N·m 136 lb ft
Differential Drain Plug 35 N·m 26 lb ft
Differential Drive Pinion Flange Nut 245 N·m 181 lb ft
Differential Fill Plug 35 N·m 26 lb ft
Differential Rear Mounting Bolts 175 N·m 129 lb ft
Propeller Shaft Coupler-to-Differential Flange Bolts 85 N·m 63 lb ft
Propeller Shaft to Transmission Output Shaft Bolts 40 N·m 30 lb ft

Lubrication Specifications
Capacities
Application
Quantity
Metric English
Synthetic Differential Lubricant GL-5 75W90 G/M P/N 89021677 (Canadian P/N 89021678)
l Drain and Fill, if differential side cover has been removed to service any internal
differential component.
For vehicles equipped the Limited Slip Differential 1.2 L 1.26 Qt
For vehicles not equipped with the Limited Slip Differential 1.3 L 1.3 Qt
l Drain and Fill with use of drain plug. 1.1 L 1.16 Qt
Important: The following is for vehicles equipped with the Limited Slip Differential option.
The Limited Slip Additive container capacity is greater than the amount needed. Only add
the amount specified.
Limited Slip Differential Lubricant Additive GM P/N 1052358 (Canadian P/N 992694)
l Drain and Fill with cover removed. 100 ml 3.38 oz
l Drain and Fill with use of drain plug. 70 ml 2.37 oz

Rear Axle Specifications
Application
Specification
Metric English
Differential Case Shim Sizes 3.5-4.4 mm 0.14-0.17 in
Pinion Housing Shim Sizes 1.2-1.9 mm 0.04-0.07 in
Pinion Rotating Torque w/Seals 2.5-4 N·m 22-35 lb in
Ring Gear/Pinion A1 Nominal Value - All Axles 111.00 mm 4.37 in
Ring Gear/Pinion A2 Nominal Value - 3.91 Ratio Axle 63.5 mm 2.50 in
Torsional Backlash
l 3.91 Ratio Axle with 105 mm Flange 0.25-0.41 mm 0.010-0.016 in

Rear Axle Usage
(1) Ratio
(2) GM Part Number
(3) Getrag Part Number
(4) Serial Number
Available Axle Ratios
Axle Ratio Drive/Engine Flange Size
3:91 RWD/2.4L L4 105 mm

Document ID: 784775
Adhesives, Fluids, Lubricants, and Sealers
Application Type of Material
GM Part Number
US Canada
Rear Differential Lubricant Axle Lubricant (Synthetic) 12378261 10953455
Pinion Nut Thread Locker 12345382 10953489
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2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Rear Drive Axle | Visual Identification |
Rear Axle Identification
(1) Axle Ratio
(2) GM Part Number
(3) Bar Code
(4) Getrag Logo
(5) Getrag Part Number
(6) Getrag Serial Number
(7) GM Logo

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Rear Drive Axle | Component Locator |
Limited Slip Differential Disassembled Views
Differential Components
(101) Bearing
(101) Bearing
(102) Bolt
(103) Differential Shaft
(104) Left Case Half
(105) Right Case Half
(106) Ring Gear
(107) Axle Side Gear
(107) Axle Side Gear
(108) Beveled Washer
(109) Plate/Separator
(109) Plate/Separator
(110) Clutch Pack
(110) Clutch Pack
(111) Pinion Gear
(111) Pinion Gear
(112) Washer © 2010 General Motors Corporation. All rights reserved.

(112) Washer

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Rear Drive Axle | Component Locator |
Rear Axle Disassembled Views
(1) Differential Carrier
(2) Carrier Cover
(3) Pinion Bearing Gage
(4) Nut
(5) Flange
(6) Pinion Oil Seal
(7) Bearing
(8) Cup
(9) Bolt
(10) Shim
(11) O-ring Seal
(12) Pinion Bearing Spacer
(13) Cup
(14) Bearing
(15) Bolt
(16) Differential Carrier Bracket
(17) Axle Oil Seal
(17) Axle Oil Seal

(18) Drain Plug
(19) Shim
(19) Shim
(20) Cup
(20) Cup
(21) O-ring Seal
(22) Vent
(23) Fill Plug
(24) Bolt
(25) Fill Plug Washer
(100) Differential Assembly
(110) Pinion Gear

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Rear Drive Axle | Repair Instructions |
Rear Axle Lubricant Level Inspection
2. Clean any dirt from around the differential fill plug.
3. Remove the fill plug from the differential and drain the fluid.
4. Check the differential fluid level. It should be even with the bottom of the fill plug hole to no
lower than 6 mm (0.25 in) below the opening.
5. Add new fluid if necessary.
6. Fill the differential with 75W90 synthetic axle lubricant. Refer to Approximate Fluid Capacities
and Lubrication Specifications.
7. Install the differential fill plug to the differential and tighten to 35 N·m (26 lb ft).
8. Lower the vehicle.

Axle Lubricant Change
Draining Procedure
2. Clean any dirt from around the differential drain plug.
3. Position a drain pan under drain plug.
4. Remove the drain plug from the differential and drain the fluid.
Filling Procedure

1. Install the drain plug to the differential and tighten to 35 N·m (26 lb ft)..
2. Clean any dirt from around the differential fill plug.
3. Remove the fill plug from the differential.
Note: If equipped with a limited slip differential, limited slip differential lubricant additive,
GM P/N 1052358 (Canadian P/N 992694) or equivalent must be added first. Refer to
Lubrication Specifications . Approximately 0.23 L (7.8 oz) of residual fluid will remain in the
differential.
4. Fill the differential with 75W90 synthetic axle lubricant, GM P/N 12378261
(Canadian P/N 10953455) or equivalent. Refer to Lubrication Specifications.
5. Inspect the gear lubricant level to ensure it is even with the bottom of the fill plug hole to no
lower than 6 mm (0.25 in) below the opening.

6. Install the fill plug to the differential and tighten to 35 N·m (26 lb ft).

Differential Carrier Cover and Seal Replacement - Left
Side
Removal Procedure
1. Remove the rear differential. Refer to Differential Replacement.
2. Remove the 9 carrier cover bolts (6).
3. Using the pry tabs (4, 5, 7), remove the carrier cover (3) from the differential carrier (1).
4. Remove the O-ring seal (2) from the cover (3).

1. Install the housing cover O-ring (2) into the groove on the housing cover (3).
2. Apply a light coat of oil to the housing cover O-ring (2) and install the housing cover (3) onto
the housing (1).
3. Install the 9 side cover bolts (4) and tighten in a criss-cross pattern to 29 N·m (21 lb ft).
4. Install the rear differential. Refer to Differential Replacement.

Output Shaft Seal Replacement
Tools Required
J 45017 Output Shaft Seal Installer
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the appropriate rear tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation .
3. Remove the appropriate wheel drive shaft. Refer to Wheel Drive Shaft Replacement .
4. Using a flat bladed tool remove the differential output shaft seal.
Take care not to damage any sealing surfaces.
1. Lubricate the wheel drive shaft sealing surface of the oil seal with 75W90 synthetic axle
lubricant, GM P/N 12378261 (Canadian P/N 10953455) or equivalent.
2. Install the differential output shaft seal (2) to the J 45017 .
3. Using the J 45017 (1), install the differential output shaft seal (2).
4. Remove J 45017 (1) from the differential output shaft seal (2).
5. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement .
6. Inspect the fluid level. Refer to Rear Axle Lubricant Level Inspection .
7. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Drive Pinion Flange/Yoke and/or Oil Seal Replacement
Special Tools
Removal Procedure
Rear.
Note: The following service procedure is for those vehicles equipped with a manual
transmission and drive line support. For vehicles equipped with a automatic transmission,
proceed to step 4.
3. Remove the propeller shaft, differential and driveline support. Refer to Propeller Shaft,
Differential, and Driveline Support Replacement.
Note: Remove only the propeller shaft coupler to differential flange bolts. DO NOT remove
the coupler from the propeller shaft.
4. Remove the propeller shaft from the rear differential. Refer to Propeller Shaft Replacement.
5. Carefully position the propeller shaft to the side and support using a suitable jack stand.
6. Remove the differential carrier bracket. Refer to Differential Carrier Bracket Replacement
• J 34826 Hub Nut Socket (36 mm)
• J 42851 Front Cover Oil Seal Installer
• J 45012 Holding Fixture
• J 45019 Flange and Pinion Cage Remover

7. Install the J 45012 to the flange.
8. While holding the J 45012 , remove the drive pinion nut using the J 34826 .
9. Remove the J 45012 from the flange.
10. Install the J 45019 to the flange.
11. Using the J 45019 , remove the flange.
12. Using a flat-bladed tool, remove the drive pinion seal. care not to damage any of the sealing
surfaces.
Note: Ensure that the pinion bore is free of dirt and debris.
1. Apply a small amount of synthetic gear oil GM P/N 121378514 (Canadian P/N 88901045) or
equivalent to the surface of the drive pinion flange and the drive pinion seal.

2. Install the drive pinion seal to the J 42851 .
3. Using the J 42851 (1) , install the drive pinion seal (2) in the differential (3).
4. Remove the J 45019 (1).
5. Install the J 45012 .
6. Install the pinion flange to the drive pinion shaft.
Note: The pinion shaft threads and pinion flange nut must be free of residue and debris prior
to application of the threadlocker.
7. Clean all the residue from the pinion shaft threads and the pinion flange nut by using
denatured alcohol or equivalent and allow to dry.
Note: Ensure that there are no gaps in the threadlocker along the length of the filled area of
the pinion shaft threads.
8. Apply the threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to 2/3 of
the threads length of the pinion shaft threads.
9. Allow the threadlocker to cure approximately 10 minutes before installation.
10. Install the drive pinion flange nut to the pinion shaft. While holding the J 45012 , use the J
34826 to tighten the drive pinion nut.
Tighten
Tighten the pinion flange nut to 245 N·m (181 lb ft).
11. Remove the J 45012 .
12. Install the differential carrier bracket. Refer to Differential Carrier Bracket Replacement

Note: The following service procedure is for those vehicles equipped with a manual
transmission and drive line support. For vehicles equipped with a automatic transmission,
proceed to step 15.
13. Install the propeller shaft, differential and driveline support. Refer to Propeller Shaft,
Differential, and Driveline Support Replacement.
14. Install the propeller shaft to the differential. Refer to Propeller Shaft Replacement.
Rear.
16. Inspect the fluid level Refer to Rear Axle Lubricant Level Inspection.

Differential Carrier Bracket Replacement
Removal Procedure
Note: Some portions of the frame and under body have been removed for the clarity of the
location of the differential carrier bracket.
Rear.
3. Support the rear differential carrier assembly with a suitable jack stand.

4. Remove the differential mounting bracket bolt (1) frame bracket.
Note: The following service procedure is to allow for enough clearance to remove the
differential mounting bracket.
5. Loosen the 2 frame bracket bolts (2).
Note: DO NOT re-use the differential carrier bracket bolts. Discard and use NEW only.
6. Remove the 4 differential carrier mounting bracket bolts (1).
7. Remove the differential carrier mounting bracket (2).
1. Remove any thread locker from the bolt holes in the differential carrier with brake clean or
equivalent.

2. Position the differential carrier bracket (2) on the differential.
3. Apply GM threadlocker P/N 89021297 (Canadian P/N 10953488) or equivalent to the NEW
differential carrier bracket bolts (1).
4. Install the 4 NEW differential carrier bracket bolts (1) and tighten to 80 N·m (59 lb ft).
5. Hand tighten the differential frame bracket to differential carrier bolt (1).
6. Install the 2 differential carrier bracket to frame bolts (2) and tighten to 110 N·m (81 lb ft)
plus 20 degrees.
7. Tighten the differential carrier bracket bolt (1) to 175 N·m (122 lb ft).

8. Remove the jack stand.
Rear.

Differential Replacement
Removal Procedure
2. Remove propeller shaft. Refer to Propeller Shaft Replacement.
3. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and
Installation.
4. Remove the right and left wheel drive shafts. Refer to Wheel Drive Shaft Replacement.
5. Position a transmission jack beneath the differential.
6. Firmly secure the differential to the transmission jack.

7. Remove the front differential carrier bracket-to-frame bolt (1).
8. Remove the left (1) and right (2) differential rear mounting bolts.
9. Lower the jack slightly until the mounting ear at the front of the differential clears the
support attachment point.
10. Remove the differential from the vehicle.
Note: The differential is shipped with a plastic vent plug. Remove the plastic vent plug prior
to differential vent installation.
1. When replacing the differential. remove the plastic vent plug and install a new differential
vent.
The vent flange must be fully seated.
2. With the differential firmly attached to the jack, raise the differential to the vehicle.

3. Hand install the differential carrier bracket-to-frame bolt (1) in order to locate the differential
to the rear support.
4. With the differential firmly attached to the jack, raise the differential to the rear support.
5. Position the differential to the support.

6. Install the left (1) and right (2) differential rear mounting bolt (1) and tighten to 175 N·m
(129 lb ft).
7. Tighten the differential carrier bracket to frame bolt and tighten to 175 N·m (129 lb ft).
8. Remove the transmission jack.
9. Install propeller shaft. Refer to Propeller Shaft Replacement.
10. Install the wheel drive shafts. Refer to Wheel Drive Shaft Replacement.
11. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
12. Inspect the differential lubricant level. Refer to Rear Axle Lubricant Level Inspection.

Limited Slip Differential Disassemble
Special Tools
J 42162 Getrag Axle Side Gear Compressor
1. Remove the 10 ring gear bolts (1) and the ring gear (3) from the differential carrier (2) using
a punch and a hammer through the bolt hole. Discard the ring gear bolt (1).
2. Pry the halves apart using the pry points.

Important: Friction discs and separator plates develop specific wear patterns. During disc
and plate removal, keep the components in the order in which they were removed.
3. Remove the axle side gear (107) and clutch pack (110) from the right half (105).
4. Remove the clutch pack and axle gear from the right half. Note the thick pressure plate (109)
side that has friction material faces away from the gear teeth.

5. Remove the beveled washer from the axle side gear. Note that the orientation of the beveled
washer (108) faces out.
6. Tag the clutch pack (110) to indicate the position of the components.

7. Using the J 42162 and a press as shown, apply light pressure so the differential shaft can be
removed.
8. Remove the differential shaft (103). Release pressure from the press.

9. Remove the pinion gears (111) and washers (112).
10. Remove the clutch pack and axle gear from the left half. Note the thick pressure plate (109)
side that has friction material faces away from the gear teeth.

11. Remove the beveled washer from the axle side gear. Note that the orientation of the beveled
washer (108) faces out.
12. Tag the clutch pack (110) to indicate the position of the components.

Limited Slip Differential Cleaning and Inspection
Warning: Refer to Safety Glasses Warning in the Preface section.
1. Clean all parts with an approved solvent.
2. Visually inspect all the parts for excessive wear or breakage. Replace the parts if necessary.
3. Inspect the pinion gear and the side gear teeth for any of the following conditions:
4. Inspect the thrust washers (112) for wear.
5. Inspect the fit of the side gears (107, 111) on the axle shafts.
6. Inspect the differential case (104, 105) for cracks and scoring.
7. Inspect the side gear bore for scoring. If scoring is present, replace the entire differential.
8. Replace the differential if there is damage to the case.
• Wear
• Cracks
• Scoring
• Spalling

Limited Slip Differential Assemble
Special Tools
J 42162 Getrag Axle Side Gear Compressor
1. Install a beveled washer (108) on the axle side gear with bevel facing out.
2. Install a thick pressure plate (109) with friction material facing away from the gear teeth.

Note: Friction discs and separator plates develop specific wear patterns. During disc and
plate installation, keep the components in the order in which they were removed.
3. Install the steel plate against friction material of the pressure plate. Alternate the installation
of steel plates and friction discs. Ensure that the last steel plate of the clutch pack (110) is
against the case half.
4. Repeat steps 1 through 3 for the other side.
5. Install the assembled axle side gear (107) into the right case half (105).
6. Align tabs on the steel plates to fit the grooves.

7. Install the assembled axle side gear (107) into the left case half (104).
8. Align tabs on the steel plates to fit the grooves.
Note: When using the hydraulic press, apply light pressure on the pinion gears and washers
so they align with the pinion differential shaft bores.
9. Using the J 42162 compressor and a press, install the pinion gears and washers.
10. Install the differential shaft (103) ensuring that it moves through the washers and gears
properly.

11. Align bolt holes between the halves and lightly press them together.
12. Install the ring gear (2) into the differential carrier (3).
13. Install 10 NEW ring gear bolts (1) in order to align the gear to the hub. Hand tighten at this
time.
14. Tighten the ring gear bolts to 185 N·m (136 lb ft)

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Wheel Drive Shafts | Component Locator |
Wheel Drive Shafts Disassembled Views
Wheel Drive Shafts Disassembled Views
(1) Shaft Clamp
(2) Outer Joint Seal
(3) Boot Insert
(4) Joint Clamp
(5) Retaining Ring, Large
(6) Retaining Ring, Small
(7) Can, Joint
(8) Outer Joint Assembly
(9) Bar, Wheel Drive Shaft
(10) Shaft Clamp

(11) Inner Joint Seal
(12) Joint Clamp
(13) Inner Joint Assembly

2009 Pontiac Solstice | SKY, Solstice (VIN M) Service Manual | Driveline/Axle | Wheel Drive Shafts | Repair Instructions |
Wheel Drive Shaft Replacement
Special Tools
Removal Procedure
Note: In the following service procedure the left side is shown, the right side is similar.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement.
Note: The wheel drive shaft spindle nut must not be reused. Replace the wheel drive shaft
spindle nut with a new nut whenever it is removed.
4. Remove and discard the wheel drive shaft spindle nut.
5. Using J-42129 Wheel Hub Remover , CJ129 Universal Hub Puller - Snap-On, 7394 Universal
Hub Puller - OTC, or equivalent, disengage the wheel drive shaft from the wheel bearing/hub.
6. Remove the adjustment link. Refer to Adjust Link Replacement.
7. Separate the upper ball joint from the rear knuckle. Refer to Knuckle Replacement.
• J-42129 Wheel Hub Remover
• J-44394 Seal Protector

8. Using a suitable tool, carefully release the wheel drive shaft from the rear differential enough
to install the J-44394 Seal Protector .
Caution: J-44394 must be installed into the differential output shaft seal prior to removing
and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the
splines of the wheel drive shaft to cut the differential output seal.
9. Carefully install the J-44394 Protector over the wheel drive shaft.
10. Carefully slide the J-44394 Protector into the differential output shaft seal.
11. Remove the wheel drive shaft from the vehicle.
12. If reusing the wheel drive shaft, remove and discard the wheel drive shaft retaining ring. The
wheel drive shaft retaining ring is on the splined shaft of the cross groove joint.

1. Install the new wheel drive shaft retaining ring. The wheel drive shaft retaining ring is on the
splined shaft of the cross groove joint.
Caution: J-44394 must be installed into the differential output shaft seal prior to removing
and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the
splines of the wheel drive shaft to cut the differential output seal.
2. If previously removed, carefully install J-44394 Protector into the differential output shaft
seal.
Note: In order to prevent lubricant leaks, use care when installing the wheel drive shaft to
the differential. Do not damage the oil seal. Replace the oil seal if it becomes nicked,
distorted, or is otherwise damaged.

3. Carefully install the wheel drive shaft into the differential until the splines are past the J-
44394 Protector . Ensure that the retaining ring is installed in the upright position.
4. Carefully remove the J-44394 Protector from the differential output shaft seal.

5. Carefully remove J-44394 Protector from the wheel drive shaft.
6. Carefully install the wheel drive shaft into the differential until the retaining ring is engaged.
7. Ensure the wheel drive shaft retaining ring is fully engaged to the differential by grasping the
inner housing and pulling outward. The wheel drive shaft will stay positively engaged if
properly installed to the differential.
8. Install the upper ball joint to the rear knuckle. Refer to Knuckle Replacement.
Note: Ensure that the drive shaft seals do not have any abrasions, cuts or punctures.
9. Loosely install the NEW wheel drive shaft spindle nut.
10. Install the adjustment link. Refer to Adjust Link Replacement.

11. Use the new wheel drive shaft spindle nut to slowly pull the spindle to the wheel hub and
bearing assembly and tighten to 215 N·m (159 lb ft).
12. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement.
13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
14. Inspect the differential lubricant level. Refer to Rear Axle Lubricant Level Inspection.

Wheel Drive Shaft Inner Joint and Boot Replacement
Note: The inner Constant Velocity Joint is not serviced separately. If the CV joint is found to have
excessive wear or damaged, replace the wheel drive shaft as an assembly.
Disassemble Procedure
1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.
2. Remove the outer CV joint and boot. Refer to Wheel Drive Shaft Outer Joint and Boot
Replacement.
Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service.
Cutting through the boot may damage the sealing surface of the housing and the tripot or
the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
3. Using the appropriate tool, remove and discard the outer boot clamp (3) and the inner boot
clamp (2) from the CV joint (4).
Note: If the boot is damaged and either the lubricant is gone, water or other foreign material
are found in the CV joint, replace the wheel drive shaft as an assembly.
• J 8059 Snap Ring Pliers
• J 42572 Drive Axle Boot Clamp Pliers

4. Remove the CV joint boot (2) from the CV joint (3) and the wheel drive shaft (1).
5. Using the appropriate cleaner, remove the lubricant from the CV joint and the wheel drive
shaft.
Assemble Procedure
1. Install the CV joint boot and clamp (1) on the wheel drive shaft and CV joint housing (2).

2. Ensure that the CV joint boot (1) is properly seated in the groove (2) in the wheel drive
shaft (3).
3. Using the J 42572 pliers , breaker bar, torque wrench and or ratchet (1), close the
clamp (2) until the gap (3) measures 1.00 mm (0.039 in).

4. Place approximately half of the lubricant (1) in the CV joint boot (2) and the other half in
the CV joint (3).
5. Install the CV joint boot and clamp (2) CV joint housing (1).
6. The measured distance (1) between the boot edges should be 88.6 mm (3.50 in)..

7. Using the J 42572 pliers (3), breaker bar (5) and a torque or racket wrench (4), close the
clamp until the gap measures 1.0 mm (0.039 in).
8. Move the CV joint in a circular motion to distribute the lubricant inside the cv joint housing.
9. Clean any remaining lubricant from the outside of the CV joint.
10. Install the outer CV joint and boot. Refer to Wheel Drive Shaft Outer Joint and Boot
Replacement.
11. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.

Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools
Note: The outer Constant Velocity Joint is not serviced separately. If the CV joint is found to have
excessive wear or damaged, replace the wheel drive shaft as an assembly.
Disassemble Procedure
1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.
2. Install the wheel drive axle shaft in a soft jawed vice.
• J 8059 Snap Ring Pliers
• J 42572 Drive Axle Boot Clamp Pliers

Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service.
Cutting through the boot may damage the sealing surface of the housing and the tripot or
the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
Note: The following proceed is for the wheel drive shaft that have the low profile boot clamp.
If the wheel drive shaft is equipped with the ear type boot clamp, proceed to step 6.
3. Using the appropriate tool, remove and discard the outer boot clamp (2) from the CV joint
boot (3).
4. Using a pair of side cutters, remove and discard the inner boot clamp (4) from the CV joint
boot (3).
5. Remove the cv joint boot (3) from the cv joint housing (1).

6. Using a pair of side cutters, remove and discard the outer boot clamp (3) and the inner boot
clamp (1).
7. Remove the cv joint boot (2) from the cv joint housing (4).
8. Using a hammer and a block of wood, remove the CV joint (2) from the wheel drive shaft (1).
9. Using the J 8059 pliers , remove the retaining ring (2) from the wheel drive shaft.

10. Remove the CV joint boot (1) from the wheel drive shaft (2).
11. If the CV joint is found to be without any lubricant, have water or any other contaminates in
it. Replace the CV joint.
Assemble Procedure
1. Position the boot and the clamp (1) on the wheel drive shaft (2), DO NOT crimp.

2. Ensure that the boot (1) is properly seated in the groove (2) in the wheel drive shaft (3).
3. Using the J 8059 pliers , install the retaining ring (2) on the wheel drive shaft (1).

4. Using the J 42572 pliers (1), close the boot clamp (2) until the gap (3) measures 1.00 mm
(0.039 in)..
5. Using a small flat bladed screwdriver, compress the retaining ring into the groove in the
wheel drive shaft to allow installation of the inner CV joint on the wheel drive shaft.

Note: The CV joint should just touch the inner retaining ring.
6. Using a block of wood and a hammer, install the CV joint (1) on the wheel drive shaft.
7. Place approximately half of the lubricant (2) inside the CV boot (1) and other half in the CV
joint (3).
8. Remove any excess lubricant on the CV joint housing or the boot.

9. Using the J 42572 pliers (3), torque or ratchet wrench (4) and breaker bar (5), close the boot
clamp until the gap (6) measures 1.0 mm (0.039 in)..
10. Move the CV joint in a circular motion 4 to 5 times to distribute the lubricant.
11. Remove the wheel drive shaft from the vise.
12. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.

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2008 PONTIAC SOLSTICE Service Repair Manual

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