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 G3500, VAN CARGO EXTENDED, 4.8 CREPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESREAR DRIVE AXLEREPAIR INSTRUCTIONSREAR AXLE HOUSING REPLACEMENT (W 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
- Install the drive pinion bearings. Refer to Drive Pinion Bearings Replacement (8.6 Inch Axle) or Drive Pinion Bearings Replacement (9.75, 10.5 and 10.75 Inch Axles) .
- 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) .
- Determine the correct shim 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) .
- 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) .
- 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) .
- Install the differential assembly. Refer to Differential Replacement (8.6 Inch Axle) or Differential Replacement (9.75, 10.5 and 10.75 Inch Axles) .
- 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) .
- Adjust the drive pinion to ring gear backlash. Refer to Pinion Depth Adjustment (8.6 Inch Axle) or Pinion Depth Adjustment (9.75, 10.5 and 10.75 Inch Axles) .
- Inspect the gear tooth contact pattern. Refer to Gear Tooth Contact Pattern Inspection .
- Install the rear brake shields. Refer to Rear Brake Shield Replacement .
- Install the rear wheel sensor ring, for the 8.6 inch axle ONLY. Refer to Rear Brake Shield Replacement .
- Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (10.5 Axle) .
- Install the rear axle cover and gasket. Refer to Rear Axle Shaft and/or Gasket Replacement .
- Install the rear axle assembly. Refer to Rear Axle Replacement .
- Fill the axle with gear 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) .
- Remove the support and 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.