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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1903 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Place a jack or utility stands, such as GMTG 123-B67313, at the rear end of the vehicle.
  3. Drain the fluid from the differential carrier assembly. Refer to Front Axle Lubricant Replacement .
    4. Fig 1: U-Joint Bearing Caps
    GM1199415Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the propeller shaft from the differential carrier assembly. Refer to Front Propeller Shaft Replacement .

    Support the propeller shaft as necessary.

  5. Remove the engine protection shield. Refer to Engine Protection Shield Replacement .
  6. Remove the front engine crossmember. Refer to Engine Front Crossmember Replacement (RWD) or Engine Front Crossmember Replacement (4WD) .
    7. Fig 2: Transmission Jack Under Differential Carrier Assembly
    GM1199384Courtesy of GENERAL MOTORS CORP.
  7. Place a transmission jack under the differential carrier assembly.

    Secure and support the differential carrier assembly to the transmission jack.

  8. Place an alignment mark between the wheel drive shafts and the inner shaft flanges.
    9. Fig 3: Wheel Drive Shaft Retaining Bolts
    GM1199394Courtesy of GENERAL MOTORS CORP.
  9. Remove the wheel drive shaft to inner shaft bolts.
    10. Fig 4: Left Wheel Drive Shaft & Front Differential Flange
    GM1199424Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the left side wheel drive shaft from the inner shaft.
    11. Fig 5: Left Side Wheel Drive Shaft From Inner Shaft
    GM1199417Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the right side wheel drive shaft from the inner shaft.
  12. Disconnect the differential carrier assembly vent hose from the differential carrier assembly.
    13. Fig 6: Upper Inner Shaft Housing Bushing Bolt & Nut - Front Drive Axle
    GM1199431Courtesy of GENERAL MOTORS CORP.
  13. Remove the upper inner shaft housing mounting bolt.
  14. Remove the upper differential carrier assembly mounting bolt.
    15. Fig 7: Removing/Installing Differential Carrier Assembly
    GM1199382Courtesy of GENERAL MOTORS CORP.
  15. Remove the differential carrier assembly.
RENDER: 1.0x

NO RELATED

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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.