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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN CARGO EXTENDED, 4.8 CREPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL REPLACEMENT (8.6 INCH AXLE)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 ring gear, if necessary. 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) .
  2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
  3. Lubricate the differential side bearings with the proper axle lubricant. Refer to Fluid and Lubricant Recommendations .
    4. Fig 1: View Of Differential Case And Axle Housing
    GM667660Courtesy of GENERAL MOTORS CORP.
  4. Install the differential assembly, with the differential bearing cups installed, into the axle housing.

    Support the differential assembly in order to keep the case from falling out of the axle housing.

  5. 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) .
  6. 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) .
  7. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
    8. Fig 2: Identifying Bearing Cap Bolt
    GM667502Courtesy of GENERAL MOTORS CORP.
  8. Install the differential bearing caps and the bolts, if necessary.
    9. NOTE: Refer to Fastener Notice .
  9. Tighten the differential bearing cap bolts.

    Tighten:  Tighten the differential bearing cap bolts to 75 N.m (55 lb ft).

  10. 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) .
  11. Fill the axle with the proper axle 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) .
  12. 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.