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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 14 (DRIVE AXLES)OVERHAULDIFFERENTIAL CASEDISASSEMBLY
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Differential Case: Disassembly

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Disassembly
WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Separate the transmission from the differential assembly, if required. Remove the carrier seal plate, automatic transmission applications, from the front of the differential housing, if required. See Fig 1. Remove the oil seal and "O" ring seal from the seal plate. Discard the oil seals.
    Fig 1: Exploded View Of Differential Carrier & Case Assembly
    G97J03673Courtesy of GENERAL MOTORS CORP.
  2. Remove the differential mount and bolts. Remove the drain plug and washer and allow the fluid to drain. Remove the fill plug, lubricant tag, and washer.
  3. Remove the vehicle speed sensor and bolt. Remove the left cover and bolts. Remove the "O" ring and oil seal from the cover. Remove the magnet from the carrier. Install the differential assembly onto the Differential Holding Fixture (J 42173).
  4. Install 4 M8 x 1.25 bolts. Tighten the bolts to 25 N.m (18 lob ft). Remove the right cover and bolts from the differential. Remove the "O" ring and oil seal from the cover.
  5. Remove the cover - rear, bolts, bolt/stud, and "O" ring. See Fig 1. Install 2 M10 x 1.5 nuts onto the transmission stud. Remove the stud from the differential. Remove the bolts and mount from the differential. Note and mark the position and direction of the mount.
  6. Remove the "C" clip from the output shaft. Install the Differential Lifting Tool (J 42155) into the groove of the output shaft in order to remove the differential case assembly.
  7. Remove the pinion housing/cage bolts. Heat the differential housing, around the pinion housing, using a Heat Gun (J 25070). Heating the housing will ease in pinion removal. Remove the pinion housing/cage assembly and shims from the differential housing. Mark or tag the shims for assembly. Locate 2 screwdrivers or pry bars to the flange area of the pinion housing/cage to ease in removal.
  8. Install the Bearing Race Remover (J 42194) into the right cover in order to remove the bearing race and shims. Position the right cover into a hydraulic press. Using a hydraulic press, remove the bearing race and shims. Mark or tag the shims for assembly.
  9. Install the Left Output Shaft Bearing Remover (J 29369-2) into the left cover bearing. Install the Slide Hammer (J 23907) to the J 29369-2 in order to remove the bearing. Remove the bearing. See Fig 2.
    Fig 2: Removing Left Output Shaft Bearing
    G00061881Courtesy of GENERAL MOTORS CORP.
  10. Install the J 42194 into the differential housing, behind the left bearing race, in order to remove the bearing race and shim. Position the housing into a hydraulic press. Using a hydraulic press, remove the race and shim or shims from the differential housing. Mark or tag the shims for assembly.
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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.