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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 417 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Turn the steering wheel all the way to the left.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Place jack or utility stands at the rear end of the vehicle.
  4. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
  5. Remove the front differential carrier assembly shield, if equipped. Refer to Shield Replacement .
  6. Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
  7. Disconnect the front propeller shaft from the differential carrier assembly. Refer to Propeller Shaft Replacement - Front in Propeller Shaft.
  8. Remove the relay rod. Refer to Relay Rod Replacement in Steering Linkage.
  9. Support the differential carrier assembly with a transmission jack or equivalent.
  10. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft, both sides.
    11. Fig 1: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle
    GM763646Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the electrical connector from the front axle actuator, S4WD axle only.
    12. Fig 2: Disconnecting Wire Harness From Front Axle Actuator (S4WD Axle Only)
    GM834234Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the wire harness from the inner axle shaft housing, S4WD axle only.
    13. Fig 3: Disconnecting Wire Harness From Inner Axle Shaft Housing (S4WD Axle Only)
    GM924830Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the wire harness from the differential carrier assembly, S4WD axle only.
    14. Fig 4: Disconnecting Wire Harness From Differential Carrier Assembly (S4WD Axle Only)
    GM924846Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the vent hose from the differential carrier assembly.
    15. Fig 5: View Of Vent Hose To Differential Carrier Assembly
    GM834272Courtesy of GENERAL MOTORS CORP.
  15. Remove the inner axle housing nuts and washers from the bracket.
    16. Fig 6: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  16. Remove the differential carrier assembly upper mounting bolt and the nut.
    17. Fig 7: View Of Differential Carrier Upper Mounting Bolt
    GM834276Courtesy of GENERAL MOTORS CORP.
  17. Pivot the differential carrier assembly forward and down on the lower mount bolt while it is being supported by the transmission jack.
  18. Secure the differential carrier assembly to the jack.
  19. Remove the differential carrier assembly lower mounting bolt and the nut.
    20. Fig 8: View Of Differential Carrier Lower Mounting Bolt
    GM834278Courtesy of GENERAL MOTORS CORP.
  20. Remove the differential carrier assembly.
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.