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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 48 (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 does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the bearing preload, backlash, and gear tooth contact pattern check in order to ensure proper contact of the gears. If you reinstall or replace the differential carrier without replacing any other component (i.e. pinion and ring gear set, bearings. etc.) then you may reinstall the carrier with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the carrier.
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the axle shafts. Refer to Rear Axle Shaft Replacement (8.6, 9.5 LD Axle)  or Rear Axle Shaft Replacement (9.5 HD Axle) .
    3. Fig 1: View Of Differential Bearing Adjuster Nut Lock/Retainer
    GM667492Courtesy of GENERAL MOTORS CORP.
  3. Remove the differential bearing adjuster nut lock (9.5/9.5 LD inch axle - right side).
    4. Fig 2: Identifying Bearing Cap Bolt
    GM667502Courtesy of GENERAL MOTORS CORP.
  4. Remove the bearing cap bolts.
  5. Remove the bearing caps. Mark the bearing caps left and right.
    6. Fig 3: View Of Pinion Shaft Contacting Axle Housing Top
    GM156411Courtesy of GENERAL MOTORS CORP.
  6. For the 8.6 inch axle, install the pinion shaft into the differential case part way and rotate the differential assembly until the pinion shaft contact the top of the axle housing.
    7. NOTE: Refer to Differential Housing Cover and Gasket Removal Notice .
  7. For the 8.6 inch axle, rotate the drive pinion clockwise in order to force the differential assembly out of the axle housing.
  8. For the 9.5/9.5 LD inch axle, loosen the differential bearing adjuster nut using the J 24429  . See Special Tools .
  9. Remove the differential assembly.
  10. Remove the bearing cups, the shims, and the spacers as necessary.

    Mark the cups and shims left and right and in the proper order as necessary. Place the cups and the shims with the bearing caps.

  11. Remove the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
  12. Remove the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
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.