Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1986CHEVY VAN G20, 5.0 H, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDRIVE AXLE - FULL FLOATINGOVERHAULDISASSEMBLY
1986 Chevrolet Chevy Van G20, 5.0 H, Standard
Drive Axle - Full Floating: Overhaul: Disassembly
1986 Chevrolet Chevy Van G20, 5.0 H, StandardSECTION Disassembly
- Drain lubricant. Remove axle shafts and housing cover. If no side play is found in the differential case assembly, mount dial indicator on pilot stud with tip against back of ring gear. Measure runout of ring gear, marking ring gear and case at point of maximum runout.
- If runout total exceeds .006" (.15 mm), ring gear could be loose or case could be damaged. Using .003" (.08 mm) feeler gauge, measure clearance between side bearing cap and outer race of side bearing. If feeler gauge can be forced between cap and race, bearing race may have been turning in carrier.
- If race has been turning, carrier could be damaged. Observe identifying letters stamped into bearing caps and face of carrier sealing surface. Left-side letters are horizontal and right-side letters are vertical. Use these matched letters for reassembly reference.
- Ensure that side bearing caps and differential carrier are marked so that caps may be reinstalled in their original positions. Remove side bearing caps. Use Housing Spreader (W-129-A on Model 44; D-167 on Models 60 and 70) to spread differential housing to .015" (.38 mm).CAUTION: DO NOT spread housing more than .020" (.51 mm). Permanent damage to housing could result.
- Mount dial indicator on pilot stud on left side of housing. Place tip against opposite side of case to measure spread. Mark point where indicator tip is placed for reassembly reference. When case is spread, remove dial indicator. See Fig 1 .
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.