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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN CARGO EXTENDED, 4.8 CREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESAXLE SHAFTSREAR DRIVE AXLEREPAIR INSTRUCTIONSREAR AXLE HOUSING REPLACEMENT (W/O VSES)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Cargo Extended, 4.8 C

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Cargo Extended, 4.8 CSECTION Installation Procedure
  1. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle)  or Drive Pinion Bearings Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  2. Install the outer pinion bearing into the axle housing.
  3. Install the drive pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  4. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6 Inch Axle)  or Pinion Depth Adjustment (9.75, 10.5 and 10.75 Inch Axles) .
  5. Install the selective shim onto the drive pinion.
  6. Install the inner pinion bearing onto the drive pinion. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle)  or Drive Pinion Bearings Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  7. Install the drive pinion. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)  or Drive Pinion and Ring Gear Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  8. Install the drive pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  9. Install the differential assembly. Refer to Differential Replacement (8.6 Inch Axle)  or Differential Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  10. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)  or Differential Carrier Bearing Preload Adjustment (9.75, 10.5 and 10.75 Inch Axle) .
  11. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment (8.6 Inch Axle)  or Backlash Adjustment (9.75, 10.5 and 10.75 Inch Axles) .
  12. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
  13. Install the rear brake shields. Refer to Rear Brake Shield Replacement .
  14. Install the hub and rotor assembly, 10.5 and 10.75 inch axles only. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement .
  15. Install the rear axle shaft bearing and the oil seal. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  16. Install the axle shafts. Refer to Rear Axle Shaft Replacement (8.6, 9.75 Inch Axle WO/RPO JL4)  or Rear Axle Shaft Replacement (8.6 Inch Axle W/RPO JL4)  or Rear Axle Shaft Replacement (9.75 Inch Axle W/RPO JL4) .
  17. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)  or Rear Axle Housing Cover and Gasket Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  18. Install the brake rotors. Refer to Rear Brake Rotor Replacement (W/Dual Wheels) or Rear Brake Rotor Replacement (Except Dual Wheels) .
  19. Install the brake caliper brackets. Refer to Rear Brake Caliper Bracket Replacement (15/25 Series) or Rear Brake Caliper Bracket Replacement (35 Series) .
  20. Install the rear axle assembly. Refer to Rear Axle Replacement .
  21. Fill the axle with lubricant. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle)  or Rear Axle Lubricant Replacement (9.75, 10.5 and 10.75 Inch Axles) .
  22. Lower the vehicle.
RENDER: 1.0x

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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.