Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSREAR AXLE REPLACEMENTINSTALLATION 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
IMPORTANT:
Observe and accurately mark the positions of all driveline components relative to the propeller shaft and axles prior to disassembly. These components include the propeller shaft, drive axles, pinion flanges, output shafts, etc. Reassemble all components in the exact relationship the components had to each other during removal. Follow specifications and torque values. Follow any measurements made prior to disassembly.
- Support the rear axle with jack or utility stands.
- Install the rear axle to the vehicle.
- Install the rear spring U-bolts, the rear spring anchor plates and the rear spring spacers to the vehicle. Refer to Leaf Spring Replacement .
- Install the lower shock absorber bolt to the rear axle. Refer to Shock Absorber Replacement .
- Install the rear axle vent hose to the rear axle.
- Install the park brake cables.
- For the left side, refer to Parking Brake Rear Cable Replacement - Left Side .
- For the right side, refer to Parking Brake Rear Cable Replacement - Right Side .
- Install the rear propeller shaft.
- For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement .
- For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement .
- Install the brake calipers. Refer to Rear Brake Caliper Replacement .
- For vehicles with RPO JL4, connect the electrical connector to the rear wheel speed sensor.
- Install the wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation .
- Fill the rear axle with the proper axle lubricant. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations .
- Remove the jack or utility stands.
- Lower the vehicle.
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.