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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 421 (REAR DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal Procedure
WARNING: This page is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove propeller shaft. Refer to Rear Propeller Shaft Replacement (AWD) or Rear Propeller Shaft Replacement (RWD) .
  3. Remove the right rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  4. Remove the right wheel drive shaft. Refer to Rear Wheel Drive Shaft Replacement .
    5. Fig 1: View Of Transmission Jack Supporting Differential
    GM787236Courtesy of GENERAL MOTORS CORP.
  5. Position a transmission jack beneath the differential.
  6. Firmly secure the differential to the transmission jack.
    7. Fig 2: View Of Front Differential-To-Support Mounting Bolt
    GM728889Courtesy of GENERAL MOTORS CORP.
  7. Remove the front differential to support mounting bolt (1) and nut.
    8. Fig 3: View Of Left Rear Differential-To-Support Mounting Bolt
    GM728891Courtesy of GENERAL MOTORS CORP.
  8. Remove the left rear differential to support mounting bolt (1).

    Note that the rear differential support mounting bolts will not be able to be removed completely due to interference with the underbody.

    9. Fig 4: View Of Right Rear Differential-To-Support Mounting Bolt
    GM728892Courtesy of GENERAL MOTORS CORP.
  9. Remove the right rear differential to support mounting bolt (1).
  10. Lower the jack slightly until the mounting ear at the front of the differential clears the support attachment point.
    11. Fig 5: View Of Wheel Drive Shaft With Rear Differential
    GM728893Courtesy of GENERAL MOTORS CORP.
  11. Using a suitable tool, carefully release the wheel drive shaft from the differential enough to install the J 44394-A  .
    12. CAUTION: J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.
  12. Carefully install J 44394-A  the over the wheel drive shaft.
  13. Carefully slide the J 44394-A  into the differential output shaft seal.
  14. Continue lowering the jack, while simultaneously disengaging the left wheel drive shaft.
  15. Remove the differential from the vehicle.
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.