Reassembling my diff last night after a reseal, come time to torque the bolts holding the pinion cartridge I referred to the FSM where it states the torque is 41 lb ft which right off the bat seemed excessive for the size bolt threading into aluminum. The 41 lb ft spec was indicated on the illustration, not trusting that I found the "Fastener Tightening Specifications" table. No where in that table is a torque for a "drive pinion cartridge bolt" as it is called out in the illustration as well as several other references indicating the same nomenclature for the pinion bearing assembly. There is a listing "Differential Housing Bolts" with a 41 lb ft torque spec yet the next one down is called "Differential Pinion Housing Bolts" which have a torque spec of 18 lb ft. Which coincidently is the torque for the side cover bolts which are the same size. Of course I didn't research this until AFTER I realized the diff carrier bolts were not cinching down, as if the threads were being pulled from the case, this was at around 30 lb ft. Can someone confirm the REAL torque of these bolts though I think I am effed with this case.

 

It is confusing. This screenshot of page 8 appears to show the bolt going into a different hole.
Page 12 shows the same 41 "ft lbs" though.

 

I noticed that as well, they show the bolt going into a drain back hole... I guess I am super picky as for awhile I created these exploded view drawing call outs for the graphic illustrator people who illustrated the FSM's and any other media that required an exploded view. In my experience most of them have no mechanical idea of what they are drawing. I don't hold that against them just stating my experience after a couple decades in the business. After posting this I called Texas Drivetrain Performance who sold me the seal kit inquiring about it. The tech was very familiar with my question as he gets a lot of them, he also confirmed the FSM is in fact incorrect. He said they (TDP) torques those bolts to 22 lb ft. which makes sense as it is an M8-1.0x30 fastener, the pinion cartridge tab the bolt passes through is 10mm thick leaving only 20mm thread engagement in aluminum which I suspect isn't the good stuff like 6061. I pulled the bolts back out and luckily it seems the threads are still ok...I hope. Torqued them to the 22 lb ft recommended and put it back together. I am planning a drivetrain change soon (auto to manual) and will address the diff at that time, I just need this one to stay together until then.

 

I remember there was that mistake in service manual. 25Nm should be right.

 

Thank you for the replies. Another shop friend confirmed the mistake as well, he agrees it should be 18 lb ft/25Nm. I guess TDP puts an extra couple pounds just because.

 

Yup. Book version is wrong. The electronic version of the service manual is correct. That's a kick in the ***** when you are trying to do the right thing.

 

I "fixed" the book with a sharpie. Nice to know the e version has been updated/corrected. Of course this was after I spent dough on the paper versions.

 

Thank you for this older thread, I just did the same thing using the factory book. Did a full turn or so at 30 ft lbs thinking it may have just been seating the pinion. Stopped because it didnt feel right, so went online and found this.
Is there a document that notes or corrects all of the errors in the book version of the factory service manual?