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 MANUALSCHEVROLET2003CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 6.0 UREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSLUBRICANT REPLACEMENT - REAR DRIVE AXLE (8.6 INCH AXLE)INSTALLATION PROCEDURE

2003 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 U

Installation Procedure

2003 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 USECTION Installation Procedure

Install a new gasket and the rear axle housing cover (2).
CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important : Do not reuse the rear axle housing cover bolts.
Install the new rear axle housing cover bolts (1).
Tighten

Tighten the bolts to 40 N.m (30 lb ft).
Fill the rear axle. Use the proper fluid.

Fig 1: Installing Rear Axle Housing Cover & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the rear axle fill plug.
Tighten

Tighten the rear axle fill plug to 33 N.m (24 lb ft).
Lower the vehicle.

Fig 2: Installing Rear Axle Fill Plug
Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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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.