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HOMESERVICE MANUALSCHEVROLET2005CHEVY EXPRESS G3500, VAN PASSENGER, LQ4REPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL REPLACEMENT (8.6 INCH AXLE)INSTALLATION PROCEDURE
2005 Chevrolet Chevy Express G3500, Van Passenger, LQ4

Installation Procedure

2005 Chevrolet Chevy Express G3500, Van Passenger, LQ4SECTION Installation Procedure
  1. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)  or Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles) .
  2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
  3. Lubricate the differential side bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
    4. Fig 1: View Of Differential Case And Axle Housing
    GM667660Courtesy of GENERAL MOTORS CORP.
  4. Install the differential assembly, with the differential bearing cups installed, into the axle housing.

    Support the differential assembly in order to keep the case from falling out of the axle housing.

  5. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment (8.6 Inch Axle)  or Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles) .
  6. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment (8.6 Inch Axle)  or Backlash Adjustment (9.75 Inch, 10.5 Inch Axles) .
  7. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
    8. Fig 2: Removing/Installing Bearing Cap Bolt
    GM667502Courtesy of GENERAL MOTORS CORP.
  8. Install the differential bearing caps and the bolts, if necessary.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Tighten the differential bearing cap bolts.

    Tighten:  Tighten the differential bearing cap bolts to 75 N.m (55 lb ft).

  10. Install the axle shafts. Refer to Rear Axle Shaft Replacement .
  11. Fill the axle with the proper axle lubricant. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles) .
  12. Lower the vehicle.
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.