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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 225 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY 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
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the differential carrier assembly to the vehicle.
  2. Connect the vent hose to the differential carrier assembly.
  3. Install the differential carrier assembly upper mounting bolt and the nut.

    Do not tighten the bolt to specification at this time.

    Fig 1: Installing Differential Carrier Assembly
    G01216416Courtesy of GENERAL MOTORS CORP.
  4. Install the inner shaft upper mounting bolt and the nut.

    Do not tighten the bolt to specification at this time.

  5. Install the front engine crossmember. Refer to Front Engine Crossmember Replacement (RWD) or Front Engine Crossmember Replacement (4WD) in Frame and Underbody .
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  6. Tighten the upper differential carrier assembly and inner shaft housing mounting bolts.

    Tighten 

    Tighten the upper differential carrier assembly and inner shaft housing mounting bolts to 85 N.m (63 lb ft).

    Fig 2: Installing Inner Shaft Upper Mounting Bolt & Nut
    G01216417Courtesy of GENERAL MOTORS CORP.
  7. Connect the left side wheel drive shaft to the inner shaft flange.

    Align the marks made during removal.

  8. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
  9. Install the left side wheel drive shaft to inner shaft bolts.

    Tighten 

    Tighten the wheel drive shaft to inner shaft flange bolts to 50 N.m (37 lb ft)

    Fig 3: Connecting Left Side Wheel Drive Shaft To Inner Shaft Flange
    G01216418Courtesy of GENERAL MOTORS CORP.
  10. Connect the right side wheel drive shaft to the inner shaft flange.

    Align the marks made during removal.

  11. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345382 (Canadian P/N 1095389) to the threads of the bolts.
      Fig 4: Connecting Right Side Wheel Drive Shaft To Inner Shaft Flange
      G01216419Courtesy of GENERAL MOTORS CORP.
  12. Install the right side wheel drive shaft to inner shaft bolts.

    Tighten 

    Tighten the wheel drive shaft to inner shaft flange bolts to 50 N.m (37 lb ft)

  13. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody .
  14. Connect the propeller shaft to the differential carrier assembly. Refer to PROPELLER SHAFT REPLACEMENT - FRONT .
  15. Fill the differential carrier assembly with the proper lubricant. Refer to Lubricant Replacement - Front Drive Axle .
  16. Remove the jack or utility stands.
  17. Lower the vehicle.
  18. Inspect the vehicle's Z height and adjust, if necessary. Refer to TRIM HEIGHT INSPECTION PROCEDURE .
    Fig 5: Installing Right Side Wheel Drive Shaft To Inner Shaft Bolts
    G01216420Courtesy of GENERAL MOTORS CORP.
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.