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HOMESERVICE MANUALSCHEVROLET1992CHEVY VAN G20, 5.7 KREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDRIVE AXLE - DANA FULL-FLOATINGOVERHAULDIFFERENTIAL ASSEMBLYDISASSEMBLY
1992 Chevrolet Chevy Van G20, 5.7 K

Differential Assembly: Disassembly

1992 Chevrolet Chevy Van G20, 5.7 KSECTION Disassembly
  1. Raise and support vehicle. Place jackstands under frame side rails. Allow rear axle housing assembly to hang free. Remove drive shaft. Remove wheel assemblies. Place drain pan under differential. Remove differential cover bolts and cover. Remove axle shafts. See AXLE SHAFTS  under REMOVAL & INSTALLATION.
  2. Note letters on bearing caps and drive axle housing for reassembly reference. Remove differential bearing caps. See Fig 2 or Fig 3 . Mount dial indicator on differential housing. See Fig 1. Preload dial indicator to .020" (.51 mm) and then return dial to zero.
    Fig 1: Spreading Drive Axle Housing
    G121080Courtesy of GENERAL MOTORS CORP.
  3. Mount Drive Axle Housing Spreader (J-24385-01 ) to differential housing. See Fig 1. Spread drive axle housing to maximum of .015" (.38 mm). Using 2 pry bars, pry differential case out of housing.
    CAUTION: DO NOT  spread housing more than .015" (.38 mm) as housing will be damaged and require replacement.
  4. Remove drive axle housing spreader. Using Differential Bearing Remover (J-29721 ), Adapters (J-29721-70 ), and Removal Plug (J-8107-03 ), remove differential case side bearings and shims. Mark bearing, race, and shims left or right side for reassembly reference.
  5. Using shop towels, place differential case in soft-jawed vise. Remove ring gear bolts. Ring gear bolts may be left-hand thread. Using a soft-faced hammer, tap ring gear off differential case.
  6. Using hammer and punch, remove pinion shaft lock roll pin from differential case. Pinion shaft is slightly press fit. Using hammer and punch, remove pinion shaft, pinion gears and thrust washers. Remove differential side gears and thrust washers. Mark all gears and washers in relation to differential case for reassembly reference.
  7. Check drive pinion bearing preload using INCH-pound torque wrench and proper socket. Record amount of torque required to start pinion to rotate. Perform preload check several times to ensure accurate reading. If drive pinion moves noticeably in and out, bearings need to be replaced.
  8. For reassembly reference, scribe mark pinion, pinion nut and pinion flange. Using Companion Flange Holder/Remover (J-8614-01 ), remove drive pinion nut. See Figure. Install Pinion Flange Remover (J-8614-1 , J-8614-2 and J-8614-3 ) through companion flange holder/remover. Tighten pinion flange remover. Remove pinion flange from pinion.
  9. Install differential cover with 2 bolts to keep drive pinion from falling out of housing during removal. Install pinion nut and tap drive pinion out of differential housing. Remover cover and retrieve drive pinion and small diameter pinion preload shims. Save shims for reassembly.
  10. Pry drive pinion oil seal from bore, being careful not to damage machined surfaces. Remove outer drive pinion bearing and oil slinger. Remove drive pinion bearing races from drive axle housing.
  11. Remove drive pinion adjustment shims and baffle (if equipped). Keep shims and baffle together for reassembly. Using Differential Side Bearing Remover (J-29721 ) and 4 Adapters (J-29721-70 ), remove inner drive pinion bearing.
    Fig 2: Exploded View Of Dana 9 3/4" Full-Floating Axle Assembly
    G121081Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.