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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISDRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESFRONT DRIVE AXLEREPAIR INSTRUCTIONSDIFFERENTIAL CARRIER ASSEMBLY DISASSEMBLYDISASSEMBLY PROCEDUREPROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Disassembly Procedure: Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Procedure
  1. Remove the inner housing to differential carrier assembly bolts.
    Fig 1: Inner Housing To Differential Carrier Assembly Bolts
    GM892376Courtesy of GENERAL MOTORS CORP.
    2. Fig 2: Inner Housing & Inner Shaft From Differential Carrier Assembly
    GM892377Courtesy of GENERAL MOTORS CORP.
  2. Remove the inner housing and inner shaft from the differential carrier assembly.
    3. Fig 3: Inner Axle Shaft In Inner Axle Housing - Front Drive Axle
    GM892402Courtesy of GENERAL MOTORS CORP.
  3. Remove the inner shaft.
  4. Install the inner shaft housing into a vise.
    5. Fig 4: View of Seal Or Seal And Bearing Using J 2619-01 - Front Drive Axle
    GM892387Courtesy of GENERAL MOTORS CORP.
  5. Install the J 29369-1  (2) and the J 2619-01  (1) behind the inner shaft bearing. See Special Tools .
  6. Remove the inner shaft bearing and inner shaft seal using the J 2619-01  .
    7. Fig 5: J 45850-2, J 45850-3 & Nuts Over Upper Inner Shaft Housing Bushing
    GM892379Courtesy of GENERAL MOTORS CORP.
  7. Install the J 45850-2 (2), J 45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the upper inner shaft housing bushing as shown.
  8. Remove the upper inner shaft housing bushing using the J 45850  . See Special Tools .
  9. Remove the inner shaft housing from the vise.
    10. Fig 6: View of Inner Shaft Housing Into A Vise
    GM892381Courtesy of GENERAL MOTORS CORP.
  10. Install the inner shaft housing into a vise so that the lower inner shaft bushing bore is flush with the jaws of the vise.
    11. Fig 7: J 45850-2, J 45850-3 & Nuts Over Lower Inner Shaft Housing Bushing
    GM892446Courtesy of GENERAL MOTORS CORP.
  11. Install the J 45850-2 (2), J 45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the lower inner shaft housing bushing as shown.
  12. Remove the lower inner shaft housing bushing using the J 45850  . See Special Tools .
  13. Remove the inner shaft housing from the vise.
  14. Install the differential carrier assembly into a vise.

    Clamp only on the mounting flange of the differential carrier assembly case.

    15. Fig 8: Left Inner Shaft
    GM892655Courtesy of GENERAL MOTORS CORP.
  15. Remove the left inner shaft using a hammer and a brass drift.
    16. Fig 9: Inner Shaft Seal Cover Bolts
    GM892661Courtesy of GENERAL MOTORS CORP.
  16. Remove the inner shaft seal cover bolts.
    17. Fig 10: Inner Shaft Seal Cover Assembly - Front Drive Axle
    GM892674Courtesy of GENERAL MOTORS CORP.
  17. Remove the inner shaft seal cover.
    18. Fig 11: Left Side Differential Bearing Adjuster Lock Bolt
    GM892676Courtesy of GENERAL MOTORS CORP.
  18. Remove the left side differential bearing adjuster lock bolt.
    19. Fig 12: Left Side Differential Bearing Adjuster Lock
    GM892677Courtesy of GENERAL MOTORS CORP.
  19. Remove the left side differential bearing adjuster lock.
    20. Fig 13: Right Side Differential Bearing Adjuster Lock Bolt
    GM892679Courtesy of GENERAL MOTORS CORP.
  20. Remove the right side differential bearing adjuster lock bolt.
    21. Fig 14: Right Side Differential Bearing Adjuster Lock
    GM892680Courtesy of GENERAL MOTORS CORP.
  21. Remove the right side differential bearing adjuster lock.
  22. Remove the differential carrier assembly from the vise.
    23. Fig 15: Differential Carrier Assembly Bolts
    GM892681Courtesy of GENERAL MOTORS CORP.
  23. Remove the differential carrier assembly bolts.
    24. Fig 16: Right Carrier Case Half From Left Carrier Case Half
    GM892683Courtesy of GENERAL MOTORS CORP.
  24. Separate the right carrier case half from the left carrier case half by tapping on the carrier case using a hammer and a brass drift.
  25. Remove the differential case assembly.
    26. Fig 17: Left Differential Bearing Adjuster
    GM896897Courtesy of GENERAL MOTORS CORP.
  26. Remove the left differential bearing adjuster by doing the following:
    1. Install the J 45224  onto the differential bearing adjuster. See Special Tools .
    2. Turn the J 45224  counterclockwise in order to remove the differential bearing adjuster. See Special Tools .
  27. Remove the differential bearing cup.
    28. Fig 18: Right Differential Bearing Adjuster & Differential Case Bearing Cup
    GM724669Courtesy of GENERAL MOTORS CORP.
  28. Remove the right differential bearing adjuster by doing the following:
    1. Install the J 45224  onto the differential bearing adjuster. See Special Tools .
    2. Turn the J 45224  counterclockwise in order to remove the differential bearing adjuster. See Special Tools .
  29. Remove the differential bearing cup.
    30. Fig 19: Left Inner Shaft Bearing
    GM720414Courtesy of GENERAL MOTORS CORP.
  30. Remove the left inner shaft bearing using the J 45232  (2) and the J 8092  (1). See Special Tools .
    31. Fig 20: J 8614-01 On Pinion Yoke
    GM896901Courtesy of GENERAL MOTORS CORP.
  31. Install the J 8614-01  onto the pinion yoke as shown. See Special Tools .

    Remove the pinion nut while holding the J 8614-01  . See Special Tools .

  32. Remove the washer.
    33. Fig 21: J 8614-2 & J 8614-3 In J 8614-01 Installed On Pinion Yoke
    GM896902Courtesy of GENERAL MOTORS CORP.
  33. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01  (1) as shown. See Special Tools .
  34. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01  (1). See Special Tools .
    35. Fig 22: J 45234 On Left Differential Carrier Case & Over Drive Pinion
    GM896911Courtesy of GENERAL MOTORS CORP.
  35. Install the J 45234  onto the left differential carrier case and over the drive pinion as shown. See Special Tools .
  36. Remove the drive pinion by turning the forcing screw of the J 45234  clockwise. See Special Tools .
  37. Remove the pinion oil seal using a suitable seal removal tool.
    38. Fig 23: Outer Pinion Bearing
    GM896916Courtesy of GENERAL MOTORS CORP.
  38. Remove the outer pinion bearing.
    39. Fig 24: View Of Collapsible Spacer & Pinion
    GM9731Courtesy of GENERAL MOTORS CORP.
  39. Remove the collapsible spacer from the pinion.
    40. Fig 25: View Of Inner Pinion Bearing & Hydraulic Press
    GM680110Courtesy of GENERAL MOTORS CORP.
  40. Remove the inner pinion bearing by installing the J 22912-B  between the pinion bearing and the pinion gear and pressing the bearing off the pinion. See Special Tools .
  41. Remove the pinion gear selectable shim.
    42. Fig 26: J 45228-4 To Outer Pinion Bearing Cup
    GM767116Courtesy of GENERAL MOTORS CORP.
  42. Install the J 45228-4 to the outer pinion bearing cup as shown.
    43. Fig 27: J 45228-1 & J 45228-5 To J 45228-4
    GM767096Courtesy of GENERAL MOTORS CORP.
  43. Install the J 45228-1 (2) and the J 45228-5 (1) to the J 45228-4.

    Seat the ridge of the J 45228-1 (2) into the outer pinion bearing cup bore.

  44. Remove the outer pinion bearing cup by turning the J 45228-5 (1) clockwise.
    45. Fig 28: J 45228-4 To Inner Pinion Bearing Cup
    GM767115Courtesy of GENERAL MOTORS CORP.
  45. Install the J 45228-4 to the inner pinion bearing cup as shown.
    46. Fig 29: J 45228-1 & J 45228-5 To J 45228-4
    GM767108Courtesy of GENERAL MOTORS CORP.
  46. Install the J 45228-1 (1) and the J 45228-5 (2) to the J 45228-4.
  47. Remove the outer pinion bearing cup by turning the J 45228-5 (2) clockwise.
    48. Fig 30: J 45850-2, J 45850-3 & Nuts On Upper Differential Carrier Assembly Bushing
    GM892404Courtesy of GENERAL MOTORS CORP.
  48. Remove the upper differential carrier assembly bushing by performing the following steps:
    1. Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown.
    2. Remove the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850  . See Special Tools .
    49. Fig 31: J 45850-2, J 45850-3 & Nuts On Lower Differential Carrier Assembly Bushing
    GM892409Courtesy of GENERAL MOTORS CORP.
  49. Remove the lower differential carrier assembly bushing by performing the following steps:
    1. Install the J 45850-2 (2), the J 45850-3 (1), the forcing screw, the thrust bearing, and the nuts (3) over the differential carrier assembly bushing as shown.
    2. Remove the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850  . See Special Tools .
RENDER: 1.0x

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