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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.3 T, 4L60E/M30REPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESAXLE SHAFTSREAR DRIVE AXLEREPAIR INSTRUCTIONSREAR AXLE SHAFT REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.3 T, 4L60E/M30

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.3 T, 4L60E/M30SECTION Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the brake caliper. Refer to Brake Caliper Replacement - Rear in Disc Brakes.
  4. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)  or Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles) .
    5. Fig 1: View Of Pinion Shaft Locking Bolt
    GM156409Courtesy of GENERAL MOTORS CORP.
  5. Remove the pinion shaft locking bolt.
    6. Fig 2: View Of Pinion Shaft
    GM156410Courtesy of GENERAL MOTORS CORP.
  6. On axles without a locking differential, remove the pinion shaft.
    7. Fig 3: Pinion Shaft Touching Housing
    GM156411Courtesy of GENERAL MOTORS CORP.
  7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
    8. Fig 4: View Of Axle Shaft, Lock & Thrust Block
    GM156412Courtesy of GENERAL MOTORS CORP.
  8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block opening (2).
  9. Push the flange of the axle shaft into the axle housing.
    10. Fig 5: Rear Axle Shaft Lock
    GM897715Courtesy of GENERAL MOTORS CORP.
  10. Remove the rear axle shaft lock from the button end of the axle shaft.
    11. Fig 6: Axle Shaft
    GM897719Courtesy 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.