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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.3 T, 4L60E/M30REPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL REPLACEMENT (9.75 INCH, 10.5 INCH AXLES)REMOVAL 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
IMPORTANT: If you remove or replace the ring and pinion gear set, perform the differential side bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings. etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement  or Rear Axle Shaft and/or Gasket Replacement .
    3. Fig 1: Differential Bearing Adjuster Nut Lock Bolts
    GM897717Courtesy of GENERAL MOTORS CORP.
  3. Remove the differential bearing adjuster nut lock bolts.
    4. Fig 2: Differential Bearing Adjuster Nut Locks
    GM897726Courtesy of GENERAL MOTORS CORP.
  4. Remove the differential bearing adjuster nut locks.
    5. Fig 3: Differential Bearing Cap Bolts
    GM897716Courtesy of GENERAL MOTORS CORP.
  5. Remove the differential bearing cap bolts.
    6. Fig 4: Differential Bearing Caps
    GM897723Courtesy of GENERAL MOTORS CORP.
  6. Remove the differential bearing caps. Mark the differential bearing caps left and right.
    7. Fig 5: Loosening Differential Bearing Adjusters
    GM897722Courtesy 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.