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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1620 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSFRONT DIFFERENTIAL CASE ASSEMBLE (9.25 INCH AXLE)ASSEMBLY PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Assembly Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Assembly Procedure
WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the pinion and side gears using axle lubricant. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    2. Fig 1: Identifying Differential Side Gears & Thrust Washers
    GM851734Courtesy of GENERAL MOTORS CORP.
  2. Install the thrust washers and the differential side gears into the differential case.

    If the same differential side gears and the thrust washers are being used, install the gears and the washers to the original locations.

    3. Fig 2: Identifying Differential Pinion Gears & Thrust Washers
    GM851732Courtesy of GENERAL MOTORS CORP.
  3. Install the differential pinion gears by performing the following steps:
    1. Position both pinion gears between the differential side gears directly opposite of each other.
    2. Rotate the differential side gears until the pinion gears are opposite the opening in the differential case in line with the pinion shaft opening.
  4. Install the thrust washers in between the pinion gear and differential case using a hammer and brass drift.
  5. Install the differential side gear spacers.
    6. Fig 3: View Of Differential & Pinion Shaft
    GM851733Courtesy of GENERAL MOTORS CORP.
  6. Install the pinion gear shaft.
    7. Fig 4: Identifying Differential Pinion Gears & Thrust Washers
    GM851732Courtesy 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.