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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.3 T, 4L60E/M30REPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESFRONT DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.3 T, 4L60E/M30

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.3 T, 4L60E/M30SECTION Installation Procedure
    Fig 1: Removing/Installing Differential Carrier Assembly
    GM1199382Courtesy of GENERAL MOTORS CORP.
  1. Install the differential carrier assembly to the vehicle.
  2. Connect the vent hose to the differential carrier assembly.
  3. Install the differential carrier assembly upper mounting bolt and the nut.

    Do not tighten the bolt to specification at this time.

    4. Fig 2: Upper Inner Shaft Housing Bushing Bolt & Nut - Front Drive Axle
    GM1199431Courtesy of GENERAL MOTORS CORP.
  4. Install the inner shaft upper mounting bolt and the nut.

    Do not tighten the bolt to specification at this time.

  5. Install the front engine crossmember. Refer to Crossmember Replacement - Front Engine (RWD) or Crossmember Replacement - Front Engine (4WD) in Frame and Underbody.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Tighten the upper differential carrier assembly and inner shaft housing mounting bolts.

    Tighten:  Tighten the upper differential carrier assembly and inner shaft housing mounting bolts to 85 N.m (63 lb ft).

    7. Fig 3: Left Wheel Drive Shaft & Front Differential Flange
    GM1199424Courtesy of GENERAL MOTORS CORP.
  7. Connect the left side wheel drive shaft to the inner shaft flange.

    Align the marks made during removal.

  8. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
  9. Install the left side wheel drive shaft to inner shaft bolts.

    Tighten:  Tighten the wheel drive shaft to inner shaft flange bolts to 50 N.m (37 lb ft)

    10. Fig 4: Left Side Wheel Drive Shaft From Inner Shaft
    GM1199417Courtesy of GENERAL MOTORS CORP.
  10. Connect the right side wheel drive shaft to the inner shaft flange.

    Align the marks made during removal.

  11. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
    12. Fig 5: Wheel Drive Shaft Retaining Bolts
    GM1199394Courtesy of GENERAL MOTORS CORP.
  12. Install the right side wheel drive shaft to inner shaft bolts.

    Tighten:  Tighten the wheel drive shaft to inner shaft flange bolts to 50 N.m (37 lb ft)

  13. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  14. Connect the propeller shaft to the differential carrier assembly. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  15. Fill the differential carrier assembly with the proper lubricant. Refer to Lubricant Replacement - Front Drive Axle .
  16. Remove the jack or utility stands.
  17. Lower the vehicle.
  18. Inspect the vehicle's Z height and adjust, if necessary. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis.
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.