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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESFRONT DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY BUSHING REPLACEMENT (INNER AXLE SHAFT HOUSING)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
    Fig 1: Lower Inner Shaft Housing Bushing Bore In Vise
    GM892385Courtesy of GENERAL MOTORS CORP.
  1. If replacing the lower inner shaft housing bushing, install the inner shaft housing bushing bore into a vise.
  2. Place the lower inner shaft housing bushing over the bushing bore.
  3. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

    Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.

  4. Install the lower inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
    5. Fig 2: Upper Inner Shaft Housing Bushing Bore In Vise
    GM892380Courtesy of GENERAL MOTORS CORP.
  5. If replacing the upper inner shaft housing bushing, install the inner shaft housing bushing bore into a vise.
  6. Place the upper inner shaft housing bushing over the bushing bore.
  7. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown.

    Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.

  8. Install the upper inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
  9. Remove the inner shaft housing from the vise.
  10. Install the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement .
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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.