Rear Drive Axle Chevrolet Chevy Express H2500

Fastener Tightening Specifications

Fastener Tightening Specifications

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Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Rear Drive Axle in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Review the system and operation in order to familiarize yourself with the system functions. Refer to Rear Drive Axle Description and Operation .

Visual/Physical Inspection

1. Inspect the system for loose or missing fasteners.
2. Inspect the system for leaking components.
3. Inspect the system for obvious damage or conditions which may cause the symptom.

Symptom List

Refer to a system diagnostic procedure from the following list in order to diagnose the symptom

1. «Rear Drive Axle Noises»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)
2. «Noisy in Drive»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)
3. «Noisy When Coasting»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)
4. «Intermittent Noise»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)
5. «Constant Noise»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)
6. «Noisy on Turns»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle)

Gear Noise

Gear noise or whine is audible from 32-89 km/h (20-55 mph) under 4 driving conditions

1. Drive - Acceleration or heavy pull
2. Road Load - Vehicle driving load or constant speed
3. Float - Using enough throttle to keep the vehicle from driving the engine, the vehicle slows down gradually but the engine still pulls slightly
4. Coast - Throttle is closed and the vehicle is in gear

Gear noise most frequently has periods where the noise is more prominent, usually between 48-64 km/h (30-40 mph) and 80-85 km/h (50-53 mph). Gear whine is corrected by either ring and pinion gear replacement or adjustment, depending on the mileage of the gearset.

Bearing Noise

Faulty bearings produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise/hum will pulsate at a constant vehicle speed. This indicates a bad pinion or a bad rear axle side bearing. This noise can be confused with rear wheel bearing noise. Inspect and replace the bearings and the affected components as required.

Rear Wheel Bearing Noise

A rough rear wheel bearing produces a noise which continues with the car coasting at low speed and the transmission in neutral. The noise may diminish some when the brakes are gently applied. The noise may also change when performing side-to-side maneuvers with the vehicle.

A rough/noisy rear wheel bearing can be heard by spinning the rear wheels by hand and listening at the hubs for the noise. Inspect and replace the bearings and the affected components as needed.

Knock at Low Speeds

A low speed knock can be caused by a differential case side gear bore that has worn oversize. Inspect the side gears and differential case and replace the components as necessary.

Backlash Clunk

Excessive backlash clunk under acceleration or de-acceleration can be caused by any of the following

1. Worn differential pinion shaft
2. Worn differential pinion and/or side gear teeth
3. Worn thrust washers
4. Excessive clearance between the side gears and the axle shafts
5. Excessive clearance between differential side gears and the bore in the case
6. Excessive drive pinon and ring gear backlash

Inspect, adjust or replace the affected components as necessary.

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Straight Roller Bearing Diagnosis

Consider the following factors when diagnosing a bearing condition

1. Note the general condition of all parts during disassembly and inspection.
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures.

Scheme 184

Light pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housings. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

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Heavy pattern on races and rollers can be caused by fine abrasives. Clean all of the parts including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

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Surface indentations in the raceway can be caused by roll either under impact loading or vibration while the bearing is not rotating. Replace the bearing if rough or noisy. Replace the shaft if damaged.

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Surface depressions on race and rollers can be caused by hard particles of foreign material. Clean all of the parts, including the housing. Check the seals. Replace the bearings if rough or noisy. Replace the shaft if damaged.

Scheme 188

Flaking of surface metal results from fatigue, usually at one edge of race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

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Flaking of surface metal results from fatigue, usually at both edges of the race and rollers. Replace the bearing. Clean all related parts. Replace the shaft if damaged.

Scheme 190

Outer misalignment due to a foreign object. Replace the bearing. Ensure races are properly seated. Replace the shaft if the bearing operating surface is damaged.

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Corrosion set up by a small relative movement of parts with no lubrication. Replace the bearing. Clean all the relative parts. Check the seals. Check for proper fit and lubrication. Replace the shaft if damaged.

Scheme 192

Smearing of metal due to slippage. Slippage can be caused by poor fits, lack of lubrication, overheating, overloads or handling damage. Replace the bearing. Clean all the related parts. Check for proper fit and lubrication.

Tapered Roller Bearing Diagnosis

Consider the following factors when diagnosing bearing condition

1. General condition of all parts during disassembly and inspection
2. Classify the failure with the aid of the illustrations.
3. Determine the cause.
4. Make all repairs following recommended procedures.

Scheme 193

Pattern on the races and the rollers caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

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Pattern on the roller ends caused by fine abrasives. Clean all of the parts and the housings. Check the seals and the bearings. Replace any leaky, rough, or noisy bearings.

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Metal smears on the roller ends due to overheating, lubricant failure, or lubricant overload. Replace the bearing. Check the seals. Check for proper lubrication.

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Bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. Replace the bearings. Check the seals. Check for proper lubrication.

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A damaged cage due to improper handling or improper tool usage. Replace the bearing.

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Wear around the outside diameter of the cage and the roller pockets caused by abrasive material. Wear caused from inefficient lubrication. Clean the related parts and the housings. Check the seals. Replace the bearings.

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Surface depressions on the race and the rollers caused by hard particles of foreign matter. Clean all the parts and the housings. Check the seals. Replace rough or noisy bearings.

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Corrosion caused by small relative movement of parts with no lubrication. Replace the bearing. Clean the related parts. Check the seals. Check for proper lubrication.

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Smearing of the metal due to slippage. Slippage can be caused by the following factors

1. Poor fits
2. Lubrication
3. Overheating
4. Overloads
5. Handling damage

Replace the bearings. Clean the related parts. Check for proper fit and lubrication.

Scheme 202

Discoloration ranging from light brown to black. This discoloration is caused from incorrect lubrication or moisture. Reuse the bearing if you can remove the stains with light polishing. Reuse the bearing if there is no evidence of overheating. Check the seals and the related parts for damage.

Scheme 203

Heat discoloration ranges from faint yellow to dark blue. This discoloration results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal. A file drawn over a hard part will glide readily with no metal cutting. Replace the bearings if overheating damage is indicated. The tempered part will fail the file test. Check the seals and the other related parts.

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A misaligned outer race due to a foreign object. Clean the related parts. Replace the bearing. Ensure the races are properly sealed.

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Cracked race due to improper fit, cocking, or poor bearing seats. Replace the bearing. Correct bearing seats.

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Flaked surface metal that results from fatigue. Replace the bearing. Clean all related parts.

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Surface indentations in the race way caused by the rollers under impact loading or caused from vibration while the bearing is not rotating. Replace a rough or noisy bearing.

Rear Axle Lubricant Leak Diagnosis

Rear axle lubricant leaks can occur at the following locations

1. Axle tube to differential carrier housing joint
2. Axle shaft oil seal
3. Axle housing porosity
4. Differential housing cover gasket
5. Drain plug
6. Fill plug
7. Pinion yoke oil seal
8. Vent tube

Determining the Cause

While most rear axle leaks may be easy to find, determining the cause may not be. A thorough inspection of the area around the leak may assist in determining the cause of the leak.

Oil Seals

Lubricant leaks from a oil seal may be caused by any of the following

1. An improperly installed seal
2. A distorted seal
3. A worn seal
4. A worn shaft
5. A brittle seal lip
6. A hardened seal lip

To determine the actual cause of the leak, clean the area around the leak. Observe the area of the leak and determine the if the seal or another component is causing the leak. A worn seal surface will cause a leak at the sealing lip while a misaligned seal or a seal installed into a housing with an excessive bore will cause the seal to leak at the outside surface of the seal. Hardened or cracked seal lips usually indicate the axle is operating beyond the normal temperature limits for the axle. A seal whose sealing surface has been nicked or cut may indicate that the shaft has a rough, burred, or gouged surface and will need to be inspected before the seal can be replaced.

Gaskets

A leak at a gasket is usually caused by a poor fit of the components on each side of the gasket surface. Inspect each component for distortion and for nicks or gouges that may prohibit the gasket from sealing properly.

Rear Axle Housing

Rear axle housing lubricant leaks usually occur at the following locations

1. Drain Plug
2. Fill Plug

Drain and fill plug leaks are usually caused by a loose plug. These leaks can by repaired by either tightening the plug or by using an approved sealer on the threads on the plug.

Other leaks such as axle tube to differential carrier housing or porosity leaks require the replacement of the rear axle housing.

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1. Raise the vehicle.
2. Make sure the vehicle is level.
3. Inspect the rear axle for leaks. Repair as necessary.
4. Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug.
6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L".
7. Insert the pipe cleaner into the fill plug opening with the stem facing down.
8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. Specification The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 in).
9. If the measurement is greater than 40 mm (1.6 in), add lubricant until the level is between 15-40 mm (0.6-1.6 in) from the bottom edge of the fill plug hole. Use the proper fluid. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
10. Install the rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft).
11. Lower the vehicle.

Scheme 209

1. Raise the vehicle.
2. Ensure the vehicle is level.
3. Inspect the rear axle for leaks. Repair as necessary.
4. Clean the area around the rear axle fill plug.
5. Remove the rear axle fill plug.
6. Inspect the lubricant level. Specification The lubricant level should be between 0-6 mm (0-0.25 in) below the fill plug opening.
7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
8. Install the rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft).
9. Lower the vehicle.

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1. Raise the vehicle.
2. Remove the rear axle fill plug.
3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts.
4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container.
5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover.
6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear.

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1. Install a new gasket and the rear axle housing cover (2). CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : Do not reuse the rear axle housing cover bolts.
2. Install the new rear axle housing cover bolts (1). Tighten Tighten the bolts to 40 N.m (30 lb ft).
3. Fill the rear axle. Use the proper fluid.
4. Install the rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft).
5. Lower the vehicle.

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1. Raise the vehicle.
2. Remove the fill plug.
3. Remove the rear axle housing cover bolts. Discard the bolts.
4. Remove the rear axle housing cover. Drain the lubricant into a suitable container.
5. Remove the sealant from the rear axle housing and the rear axle housing cover.

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1. Apply an approximately 3.18-6.35 mm (1/8-1/4 in) high and 3.18-6.35 mm (1/8-1/4 in) wide bead of sealant, GM P/N 12346240 (Canadian P/N 10953493) or equivalent, to the rear axle housing cover. The sealant is to be applied in the middle of the rear axle housing cover flange and on the inside of all bolt hole openings as shown.
2. Install the rear axle housing cover. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the new rear axle housing cover bolts. Tighten Tighten the rear axle housing cover bolts to 61 N.m (45 lb ft). Important : Allow the sealant to cure for 1 hour before filling the axle with axle lubricant.
4. Fill the rear axle with axle lubricant. Use the proper fluid.
5. Install rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft).
6. Lower the vehicle.

Removal Procedure

Important : Make note of the routing in order to aid in reassembly.

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1. Raise the vehicle.
2. For 15 series vehicles, remove the vent hose from the clip attached to the frame.
3. Remove the vent hose from the axle.
4. For 25/35 series vehicles, remove the vent hose from the clip attached to the frame.
5. Remove the vent hose from the axle.

Installation Procedure

Important : When installing the vehicle hose, note the following

1. Route the same way as when removed.
2. Ensure that the hose is free of kinks and is routed clear of sharp objects.
3. Ensure that the vent is not plugged.

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1. For 15 series vehicles, install the vent hose to the axle.
2. Install the vent hose to the clip attached to the frame.
3. For 25/35 series vehicles, install the vent hose to the axle.
4. Install the vent hose to the clip attached to the frame.
5. Lower the vehicle.

Scheme 221

1. Raise the vehicle.
2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug.
4. Remove the rear axle housing cover bolts. Discard the rear axle housing cover bolts.
5. Carefully remove the rear axle housing cover from the axle housing and drain the lubricant into a suitable container.
6. Remove any gasket material from the rear axle housing and/or the rear axle housing cover.
7. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation may be a indication of extreme wear.

Scheme 222

1. Install the rear axle housing cover and a new gasket onto the axle housing. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : Do not reuse the rear axle housing cover bolts.
2. Install the new rear axle housing cover bolts. Tighten Tighten the rear axle housing cover bolts in a crosswise pattern to 40 N.m (30 lb ft).
3. Fill the rear axle using the proper fluid.
4. Install the rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft)
5. Lower the vehicle.

Scheme 223

1. Raise the vehicle.
2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug.
4. Remove the rear axle housing cover bolts. Discard the rear axle housing cover bolts.
5. Carefully remove the rear axle housing cover from the axle housing and drain the lubricant into a suitable container.
6. Remove any sealant from the rear axle housing and/or the rear axle housing cover.
7. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation may be a indication of extreme wear.

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1. Apply an approximately 3.18-6.35 mm (1/8-1/4 in) high and 3.18-6.35 mm (1/8-1/4 in) wide bead of sealant, GM P/N 12346240 (Canadian P/N 10953493) or equivalent, to the rear axle housing cover. The sealant is to be applied in the middle of the rear axle housing cover flange and on the inside of all bolt hole openings as shown.
2. Install the rear axle housing cover. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : Do not reuse the rear axle housing cover bolts.
3. Install the new rear axle housing cover bolts. Tighten Tighten the rear axle housing cover bolts to 61 N.m (45 lb ft). Important : Allow the sealant to cure for 1 hour before filling the axle with axle lubricant.
4. Fill the rear axle with axle lubricant. Use the proper fluid. .
5. Install rear axle fill plug. Tighten Tighten the rear axle fill plug to 33 N.m (24 lb ft).
6. Lower the vehicle.

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1. Raise the vehicle.
2. Remove the tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
4. Remove the rear axle housing cover and the gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
5. Remove the pinion shaft locking bolt.
6. On axles without a locking differential, remove the pinion shaft.
7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the rear axle shaft lock (1) until the lock aligns with the thrust block opening (2).
9. Push the flange of the axle shaft into the axle housing.
10. Remove the rear axle shaft lock from the button end of the axle shaft. Important : When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult.
11. Remove the axle shaft from the housing.

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1. Install the axle shaft into the rear axle housing. Rotate the axle shaft as necessary in order to align the axle shaft splines with the differential side gear splines and engage the differential side gear.
2. On axles without a locking differential, place the rear axle shaft lock on the button end of the axle shaft.
3. On axles with a locking differential, install the rear axle shaft lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2) as shown.
4. Pull the shaft flange outward in order to seat the rear axle shaft lock in the differential side gear.
5. Install the pinion shaft into the differential case. Align the hole in the pinion shaft with the bolt hole in the differential case. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
6. Install the new pinion shaft locking bolt. Tighten For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N.m (27 lb ft). For the 9.75 inch axle, tighten the pinion shaft locking bolt to 27 N.m (20 lb ft).
7. Install the rear axle housing cover and the gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
8. Install the brake caliper. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
9. Install the tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
10. Fill the rear axle. Use the proper fluid.
11. Lower the vehicle.

Rear Axle Shaft Seal and/or Bearing Replacement

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 21128 Axle Pinion Oil Seal Installer
3. J 23690 Bearing Installer
4. J 2619-01 Slide Hammer
5. J 29712 Wheel Bearing Remover
6. J 44685 Rear Axle Seal and Bearing Remover
7. J 45853 Rear Axle Bearing/Seal Installer

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1. Raise the vehicle.
2. Remove the axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
3. If replacing only the axle shaft seal, remove the seal using a suitable seal removal tool.
4. If replacing the rear axle shaft seal and the bearing on the 8.6 inch axle, install the J 44685 (1) and the J 2619-01 (2) into the axle housing behind the axle bearing.
5. Remove the axle shaft seal and the bearing by pulling on the J 2619-01 .
6. If replacing the rear axle shaft seal and the bearing on the 9.75 inch axle, install the J 29712 into the axle housing behind the axle bearing.
7. Remove the axle shaft seal and the bearing by tightening the nut on the J 29712 .

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Scheme 240

1. Install the axle shaft bearing using the J 23690 , 8.6 inch axle, or the J 45853 , 9.75 inch axle (1) and the J 8092 (2).
2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube.
3. For the 8.6 inch axle, install the axle shaft seal using the J 21128 . Ensure the seal is fully seated in the axle tube.
4. For the 9.75 inch axle, install the axle shaft seal using the J 45853 (2) and the J 8092 (1). Ensure the seal is fully seated in the axle tube.
5. Install the axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
6. Fill the rear axle. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
7. Lower the vehicle.

Scheme 241

1. Raise the vehicle.
2. Remove the tire and wheel. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the flange bolts.
4. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft.
5. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal.
6. Remove the axle shaft from the tube.
7. Remove the gasket.
8. Clean the axle shaft flange and the outside face of the hub assembly.

Scheme 242

1. Install the gasket onto the axle shaft.
2. Install the gasket and the axle shaft into the axle tube. Ensure the shaft splines mesh into the differential side gear. Align the holes in the axle flange and the gasket with the holes in the hub. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the axle flange bolts. Tighten Tighten the rear axle flange bolts to 156 N.m (115 1b ft).
4. Install the tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
5. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Level Inspection - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
6. Lower the vehicle.

Rear Axle Hub, Bearing, Cup, and/or Seal Replacement

Tools Required

1. J 8092 Universal Driver Handle - 3/4 inch - 10
2. J 2222-C Wheel Bearing Nut Wrench
3. J 24426 Wheel Bearing Race Installer - Outer
4. J 24427 Wheel Bearing Race Installer - Inner
5. J 44419 Hub Outer Bearing Race Installer
6. J 44420 Differential Bearing and Hub Seal Installer

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Scheme 251

1. Raise the vehicle.
2. Remove the tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
4. Remove the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
5. Remove the axle nut retaining ring.
6. Remove the key.
7. Remove the adjusting nut using the J 2222-C .
8. Remove the adjusting nut.
9. Remove the hub from the axle housing.
10. Remove the rotor, if necessary. Refer to «BRAKE ROTORS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
11. Remove the oil seal from the wheel hub using a suitable seal removal tool.
12. Remove the inner hub bearing.
13. Remove the inner hub bearing cup using a brass drift and a hammer.
14. Remove the retaining ring from the wheel hub.
15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1).

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

1. Lubricate the following with a light coat of high melting point EP bearing lubricant: The outer wheel bearing The inner wheel bearing The outer wheel bearing cup The inner wheel bearing cup The axle housing
2. Install the outer bearing into the wheel hub.
3. Install the outer bearing cup into the wheel hub.
4. Drive the bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1).
5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove.
6. Install the inner bearing cup.
7. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1).
8. Install the inner bearing. Important : Each time you, replace the wheel hub bearings, install a new oil seal in order to prevent the wheel hub from leaking.
9. Install the new oil seal using the J 44420 (2) and the J 8092 (1).
10. Install the rotor, if necessary. Refer to «BRAKE ROTORS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle.
12. Install the wheel hub to the axle housing.
13. Install the adjusting nut to the hub using the J 2222-C .
14. Adjust the wheel bearings. Refer to «Wheel Bearing Adjustment»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
15. Install the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
16. Install the brake caliper. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
17. Install the tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
18. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Level Inspection - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
19. Lower the vehicle.

Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)

Tools Required

1. J 8614-01 Flange and Pulley Holding Tool
2. J 38694 Extension Housing Oil Pump/Seal Installer

Important : Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly.

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

1. Raise the vehicle.
2. Remove the tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the rear brake calipers. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4).
5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary.
6. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: The pinion bearings The pinion oil seal The differential case bearings The axle bearings The axle seals
7. Scribe an alignment line between the pinion shaft and the pinion yoke.
8. Install the J 8614-01 as shown.
9. Remove the pinion nut while holding the J 8614-01 . Discard the pinion nut.
10. Remove the washer.
11. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
12. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant.
13. Remove the pinion oil seal using a suitable seal removal tool.

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

1. Install a new pinion oil seal using the J 38694 .
2. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
3. Install the pinion yoke. Align the marks made during removal. CAUTION: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
5. Install the washer. Important : Do not reuse the pinion nut.
6. Install the new pinion nut.
7. Install the J 8614-01 onto the pinion yoke as shown. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
8. Tighten the pinion nut while holding the J 8614-01 . Tighten Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
9. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in) greater than the rotating torque recorded during removal.
10. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
11. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal.
12. Install the propeller shaft yoke retaining clamps and the bolts. Tighten Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft).
13. Install the brake calipers. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
14. Install the tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Level Inspection - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
16. Lower the vehicle.

Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)

Tools Required

1. J 8614-01 Flange and Pulley Holding Tool
2. J 45710 Pinion Bearing Oil Seal Installer

Important : Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly.

Scheme 272

Scheme 273

Scheme 274

Scheme 275

1. Raise the vehicle.
2. Disconnect the propeller shaft from the rear axle pinion yoke. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) and «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
3. Place an alignment mark between the pinion and the pinion yoke.
4. Install the J 8614-01 as shown.
5. Remove the pinion nut while holding the J 8614-01 .
6. Remove the washer.
7. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
8. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant.
9. Remove the pinion oil seal using a suitable seal removal tool.

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

1. Install the new seal using the J 45710 .
2. Install the pinion yoke. CAUTION: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
3. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
4. Install the washer. Important : Do not reuse the pinion nut.
5. Install the new pinion nut
6. Install the J 8614-01 onto the pinion yoke as shown. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
7. Tighten the pinion nut while holding the J 8614-01 . Tighten Tighten the pinion nut to 339 N.m (250 lb ft).
8. Install the propeller shaft to the rear axle pinion yoke. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) and «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
9. Inspect and add axle lubricant to the axle housing, if necessary. Refer to «Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Level Inspection - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
10. Lower the vehicle.

Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)

Tools Required

J 22536 Pinion Driver

Scheme 281

Scheme 282

Scheme 283

Scheme 284

1. Raise the vehicle.
2. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
3. Remove the pinion yoke and the oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
4. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion.
5. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
6. Remove the collapsible spacer from the pinion. Discard the spacer.
7. Remove the pinion bearings and the cups. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) . Important : The ring gear bolts have left-hand threads.
8. Remove the ring gear bolts. Discard the bolts. CAUTION: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.
9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

Important : The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

Scheme 285

Scheme 286

1. Install the ring gear to the differential case. Important : The ring gear bolts have left-hand threads.
2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the ring gear bolts in sequence to 120 N.m (89 lb ft).
4. Install the pinion bearing cups. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .
5. Determine the selective shim thickness for the pinion gear. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-86-inch-axle) or «Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-975-inch-105) .
6. Install the selective shim onto the pinion.
7. Install the inner pinion bearing to the pinion. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .
8. Install a new collapsible spacer.
9. Lubricate the pinion bearings with axle lubricant.
10. Install the outer pinion bearing into the axle housing.
11. Install the new pinion oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
12. Install the pinion into the axle housing.
13. Install the pinion yoke. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
14. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
15. Fill the axle with lubricant. Use the proper fluid. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
16. Lower the vehicle.

Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)

Tools Required

J 22536 Pinion Driver

Scheme 287

Scheme 288

Scheme 289

Scheme 290

1. Raise the vehicle.
2. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
3. Remove the drive pinion yoke and the pinion oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
4. Remove the thrust washer.
5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion.
6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
7. Remove the pinion preload shims from the drive pinion and set aside.
8. Remove the inner pinion bearing and the pinion position shim. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) . Important : The ring gear bolts have right-hand threads.
9. Remove the ring gear bolts. Discard the bolts. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
10. Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary.

Scheme 291

Scheme 292

1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-86-inch-axle) or «Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-975-inch-105) . Important : The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
2. Install the ring gear to the differential case. Align the holes in the differential case to the bolts holes in the ring gear. Important : The ring gear bolts have right-hand threads.
3. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten Tighten the new ring gear bolts to 177 N.m (131 lb ft).
5. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
6. Fill the axle with lubricant. Use the proper fluid. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
7. Lower the vehicle.

Drive Pinion Bearings Replacement (8.6 inch Axle)

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 8611-01 Rear Pinion Bearing Race Installer
3. J 8614-01 Flange and Pulley Holding Tool
4. J 22912-01 Split-Plate Bearing Puller
5. J 38694 Extension Housing Oil Pump/Seal Installer
6. J 45870 Pinion Bearing Cup Installer

Scheme 293

Scheme 294

Scheme 295

1. Raise the vehicle.
2. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
3. Remove the drive pinion from the axle. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
4. Press the bearing off of the drive pinion using the J 22912-01 .
5. Remove the selective pinion shim.
6. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.
7. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

1. Install the outer pinion bearing cup using the J 8611-01 (1) and the J 8092 (2).
2. Install the inner pinion bearing cup using the J 45870 (2), and the J 8092 (1).
3. Determine the selective shim thickness for the drive pinion. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-86-inch-axle) or «Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-975-inch-105) .
4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.
5. Install the inner pinion bearing using the J 24433 . Press the bearing on until the cone seats on the pinion shim.
6. Install a new collapsible spacer.
7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid.
8. Install the outer pinion bearing into the axle housing.
9. Install a new pinion oil seal using the J 38694 .
10. Install the pinion into the axle housing.
11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
12. Install the pinion yoke. Align the marks made during removal. CAUTION: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.
13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few threads show through the yoke.
14. Install the washer. Important : Do not reuse the pinion nut.
15. Install the new pinion nut.
16. Install the J 8614-01 onto the pinion yoke as shown. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.
17. Tighten the pinion nut while holding the J 8614-01 . Tighten Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
18. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.
19. If the rotating torque measurement is below 1.0 N.m (10 lb in) for used bearings, or 1.7 N.m (15 lb in) for new bearings, continue to tighten the pinion nut. Tighten Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings.
20. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
21. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
22. Fill the axle with the proper axle lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
23. Lower the vehicle.

Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)

Tools Required

1. J 22536 Pinion Driver
2. J 22912-01 Split-Plate Bearing Puller
3. J 42176 Universal Driver Handle - Non-Threaded
4. J 45703 Pinion Bearing Race Remover - Dana 248
5. J 45704 Pinion Bearing Race Installer- Dana 248
6. J 45705 Pinion Bearing Race Remover - Dana 248/267
7. J 7818 Inner Bearing Race Installer
8. J 8092 Universal Drive Handle - 3/4 in - 10

Scheme 303

Scheme 304

Scheme 305

Scheme 306

1. Raise the vehicle.
2. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
3. Remove the pinion yoke and the pinion oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
4. Remove the thrust washer.
5. Install the J 22536 as shown. Ensure that the J 22536 is firmly seated on the pinion.
6. Drive the pinion out using the J 22536 and a hammer. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.
7. Remove the pinion preload shims, both axles, and the pinion spacer, 10.5 inch axle only, from the drive pinion and set aside.
8. Remove the inner pinion bearing cup and the oil deflector using the J 45703 , 9.75 inch axle, or the J 45706 , 10.5 inch axle (2) and the J 42176 (1).
9. Remove the outer pinion bearing cup using the J 45705 and the J 42176 .
10. Remove the inner pinion bearing using the J 22912-01 and a hydraulic press.
11. Remove the selective pinion shim.

Scheme 307

Scheme 308

1. For the 9.75 inch axle, install the inner pinion bearing cup using the J 45704 (2) and the J 8092 (1).
2. For the 10.5 inch axle, install the inner pinion bearing cup using the J 44417 (2) and the J 8092 (1).
3. Install the outer pinion bearing cup using the J 7818 (2) and the J 8092 (1).
4. Determine the selective pinion shim thickness and the pinion preload shim thickness for the drive pinion. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-86-inch-axle) or «Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-975-inch-105) .
5. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
6. Fill the axle with the proper axle lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
7. Lower the vehicle.

Important : Group and mark the shims together as originally removed. If you remove or replace the ring and pinion gear set, perform the differential side 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 assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings, etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

Scheme 309

Scheme 310

1. Raise the vehicle.
2. Remove the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the differential bearing caps and bolts. Mark the differential bearing caps left and right. WARNING: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case. CAUTION: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.
4. Remove the differential by prying the differential from the axle housing at the differential window.
5. Remove the differential 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 differential bearing caps.
6. Remove the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .
7. Remove the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .

Scheme 311

Scheme 312

1. Install the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
2. Install the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .
3. Lubricate the differential side bearings with the proper axle lubricant.
4. Place 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. Install the differential bearing caps and the bolts. Do not torque the differential bearing cap bolts at this time.
6. Adjust the differential side bearing preload. Refer to «Differential Side Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-86) or «Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-975) .
7. Adjust the drive pinion to ring gear backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-86-inch-axle) or «Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-975-inch-105-inch) .
8. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) . CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
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»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
11. Fill the axle with the proper axle lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
12. Lower the vehicle.

Differential Replacement (9.75 Inch, 10.5 Inch Axles)

Tools Required

J 24429 Side Bearing Backlash Spanner

Important : If you remove or replace the ring and pinion gear set, perform the differential side 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 assembly without replacing any other component (i.e. pinion and ring gear set, differential bearings, etc.) then you may reinstall the differential assembly with the original shims in their original locations. Always perform a gear tooth contact pattern check, even when you remove only the differential assembly.

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

1. Raise the vehicle.
2. Remove the rear axle housing cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the differential bearing adjuster nut lock bolts.
5. Remove the differential bearing adjuster nut locks.
6. Remove the differential bearing cap bolts.
7. Remove the differential bearing caps. Mark the differential bearing caps left and right. WARNING: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case. CAUTION: When removing the differential case from the axle housing, do not damage the cover gasket surface. If the cover gasket surface is damaged, lubricant may leak from the axle and cause premature failure of the axle assembly.
8. Loosen the differential bearing adjusters using the J 24429 .
9. Remove the differential assembly.
10. Remove the differential bearing cups. Mark the differential bearing cups left and right. Place the differential bearing cups with the differential bearing caps.
11. Remove the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .
12. Remove the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Install the ring gear, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
2. Install the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .
3. Lubricate the differential side bearings with the proper axle lubricant.
4. Place 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. Install the differential bearing caps.
6. Install the differential bearing cap bolts. Do not torque the differential bearing cap bolts to specification at this time.
7. Turn the adjusters evenly on each side using the J 24429 until snug against the differential.
8. Adjust the differential side bearing preload. Refer to «Differential Side Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-86) or «Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-975) .
9. Adjust the drive pinion to ring gear backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-86-inch-axle) or «Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-975-inch-105-inch) .
10. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) . CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
11. Tighten the differential bearing cap bolts. Tighten Tighten the differential bearing cap bolts to 109 N.m (80 lb ft).
12. Install the differential bearing adjuster retainers.
13. Install the differential bearing adjuster retainer bolts. Tighten Tighten the differential bearing adjuster retainer bolts to 13 N.m (10 lb ft).
14. For the 9.75 inch axle, install the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
15. For the 10.5 inch axle, install the axle shafts and new axle shaft gaskets. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
16. Install the rear axle housing cover. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
17. Fill the axle with the proper axle lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
18. Lower the vehicle.

Differential Side Bearings Replacement

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 21784 Side Bearing Installer
3. J 22888-D Side Bearing Remover Kit
4. J 24430 Differential Side Bearing Installer
5. J 36597 Side Bearing Puller Pilot - 9.25 inch
6. J 45711 Differential Side Bearing Remover - Dana 248
7. J 45900 Differential Side Bearing Installer - Dana Axles
8. DT 46725 Side Bearing Installer

Scheme 323

Scheme 324

1. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
2. For the 8.6 inch axle and 10.5 inch axle with RPO G80, remove the differential side bearing by performing the following steps: Install the differential assembly in a vise. Install the J 22888-20A (2) and the J 8107-4 , 8.6 inch axle, or the J 8107-3 , 10.5 inch axle (1) as shown. Remove the differential side bearing using the J 22888-20A .
3. Remove the differential assembly from the vise.
4. For the 9.75 inch axle, remove the differential side bearings by performing the following steps: Install the J 45711 (2) and the J 36597 (1) as shown. Remove the differential side bearing using the J 45711 and a hydraulic press.
5. For the 10.5 inch axle without RPO G80, remove the differential side bearing cage and roller bearings from the inner bearing race.
6. Remove the inner bearing race from the differential assembly using a suitable method that will not damage the differential case.

Scheme 325

1. In order to protect the differential case, install the J 8107-4 , 8.6 inch axle, or the J 36597 , 9.75 inch axle, or J 8107-3 , 10.5 inch axle, in the case on the side opposite the bearing installation.
2. Install the bearing on top of the differential case.
3. Install the differential side bearing onto the differential case by doing the following: Install one of the following side bearing installers to the J 8092 (1) and place over the differential side bearing as shown: For the 8.6 inch axle, use J 21784 (2) For the 9.75 inch without RPO G80 or 10.5 inch axles, use J 24430 or the J 45900 (2) For the 9.75 inch with RPO G80, use DT 46725 (2) Drive the bearing onto the differential case using the J 21784 , the J 24430 , the J 45900 , or the DT 46725 and the J 8092 .
4. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .

Important : Observe and accurately mark the positions of all driveline components relative to the propeller shaft and axles prior to disassembly. These components include the propeller shaft, drive axles, pinion flanges, output shafts, etc. Reassemble all components in the exact relationship the components had to each other during removal. Follow specifications and torque values. Follow any measurements made prior to disassembly.

1. Raise the vehicle.
2. Place jack or utility stands (such as GMDE 123-1367313) at the front end of the vehicle.
3. Support the rear axle with jack or utility stands.
4. Remove the wheel and tire assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
5. Remove the brake calipers from the rear axle. It is not necessary to disconnect the brake hose from the caliper. Support the brake calipers as necessary and set aside. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
6. Disconnect the propeller shaft from the rear axle. Support the propeller shaft as necessary and set aside. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
7. Disconnect the rear park brake cables. Refer to «PARK BRAKE CABLE»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
8. Drain the lubricant from rear axle. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
9. Remove the rear axle vent hose from the axle.
10. Disconnect the lower portion of the shock absorber from the rear axle. Refer to «SHOCK ABSORBER REPLACEMENT»(/chevrolet/chevy-express-h2500/2003-2003/remont/suspension-rear/#rear-suspension-system) .
11. Remove the rear spring U-bolts, the rear spring anchor plates and the rear spring spacers from the vehicle. Refer to «LEAF SPRING REPLACEMENT»(/chevrolet/chevy-express-h2500/2003-2003/remont/suspension-rear/#rear-suspension-system) .
12. Remove the rear axle from the vehicle.

Important : Observe and accurately mark the positions of all driveline components relative to the propeller shaft and axles prior to disassembly. These components include the propeller shaft, drive axles, pinion flanges, output shafts, etc. Reassemble all components in the exact relationship the components had to each other during removal. Follow specifications and torque values. Follow any measurements made prior to disassembly.

1. Install the rear axle to the vehicle. Support the rear axle with jack or utility stands.
2. Install the rear spring U-bolts, the rear spring anchor plates and the rear spring spacers to the vehicle. Refer to «LEAF SPRING REPLACEMENT»(/chevrolet/chevy-express-h2500/2003-2003/remont/suspension-rear/#rear-suspension-system) .
3. Connect the lower portion of the shock absorber to the rear axle. Refer to «SHOCK ABSORBER REPLACEMENT»(/chevrolet/chevy-express-h2500/2003-2003/remont/suspension-rear/#rear-suspension-system) .
4. Install the rear axle vent hose to the rear axle.
5. Connect the park brake cable to the rear axle. Refer to «PARK BRAKE CABLE»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
6. Connect the propeller shaft to the rear axle. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(/chevrolet/chevy-express-h2500/2003-2003/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
7. Install the brake calipers. Refer to «BRAKE CALIPERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
8. Install the wheel and tire assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
9. Fill the rear axle with the proper axle lubricant.
10. Remove the jack or utility stands.
11. Lower the vehicle.

1. Raise the vehicle.
2. Drain the axle lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the rear axle assembly. Refer to «Rear Axle Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
4. Remove the brake caliper brackets. Refer to «BRAKE CALIPER BRACKETS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes__brake-caliper-brackets) .
5. Remove the brake rotors. Refer to «BRAKE ROTORS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
6. Remove the hub and rotor assembly, 10.5 inch axle only. Refer to «Rear Axle Hub, Bearing, Cup, and/or Seal Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-hub-bearing-cup-andor) .
7. Remove the rear axle housing cover and gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
8. Remove the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
9. Remove the brake backing plates. Refer to «REAR DISC BRAKE BACKING PLATE»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
10. Remove the rear axle shaft oil seal and the bearing. Refer to «Rear Axle Shaft Seal and/or Bearing Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-shaft-seal-andor-bearing) .
11. Remove the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
12. Remove the drive pinion shaft yoke and the oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
13. Remove the drive pinion and the inner pinion bearing. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
14. Remove the pinion bearing cups. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .

1. Install the pinion bearing cups. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .
2. Install the outer pinion bearing into the axle housing.
3. Install the drive pinion oil seal. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
4. Determine the selective shim thickness for the drive pinion. Refer to «Pinion Depth Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-86-inch-axle) or «Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__pinion-depth-adjustment-975-inch-105) .
5. Install the selective shim onto the drive pinion.
6. Install the inner pinion bearing onto the drive pinion. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .
7. Install the drive pinion. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
8. Install the drive pinion yoke. Refer to «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) or «Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-flangeyoke-andor-oil-seal) .
9. Install the differential assembly. Refer to «Differential Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Differential Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-replacement-975-inch-105-inch) .
10. Adjust the differential side bearing preload. Refer to «Differential Side Bearing Preload Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-86) or «Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearing-preload-adjustment-975) .
11. Adjust the drive pinion to ring gear backlash. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-86-inch-axle) or «Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-975-inch-105-inch) .
12. Perform a gear tooth contact pattern check. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .
13. Install the brake backing plates. Refer to «REAR DISC BRAKE BACKING PLATE»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
14. Install the hub and rotor assembly, 10.5 inch axle only. Refer to «Rear Axle Hub, Bearing, Cup, and/or Seal Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-hub-bearing-cup-andor) .
15. Install the rear axle shaft bearing and the oil seal. Refer to «Rear Axle Shaft Seal and/or Bearing Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__rear-axle-shaft-seal-andor-bearing) .
16. Install the axle shafts. Refer to «Rear Axle Shaft Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
17. Install the rear axle housing cover and gasket. Refer to «Rear Axle Housing Cover and Gasket Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Rear Axle Housing Cover and Gasket Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
18. Install the brake rotors. Refer to «BRAKE ROTORS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes) .
19. Install the brake caliper brackets. Refer to «BRAKE CALIPER BRACKETS»(/chevrolet/chevy-express-h2500/2003-2003/remont/mechanical-hydraulic/#disc-brakes__brake-caliper-brackets) .
20. Install the rear axle assembly. Refer to «Rear Axle Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
21. Fill the axle with lubricant. Refer to «Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Replacement - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
22. Lower the vehicle.

Scheme 326

Scheme 327

Scheme 328

1. Remove the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) . Important : The ring gear bolts on the 8.6 inch axle have left-hand threads. The ring gear bolts on the 9.75 inch and 10.5 inch axles have right-hand threads
2. Remove the gear bolts. Discard the bolts. CAUTION: Do not pry the ring gear from the differential case. Prying the ring gear from the differential case may cause damage to the ring gear and/or the differential case.
3. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary.
4. Remove the differential pinion gears and the differential side gears by performing the following steps: For the 8.6 inch and 9.75 inch axles, remove the pinion shaft lock bolt. For the 10.5 inch axle, remove the pinion shaft pin using a hammer and drift pin. Remove the pinion shaft. Roll the differential pinion gears out of the case with the pinion gear thrust washers. Remove the differential side gears and the side gear thrust washers. Mark the pinion gears top and bottom and the differential side gears left and right.

Scheme 329

Scheme 330

Scheme 331

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid.
2. Install the differential side gear thrust washers to the differential side gears.
3. Install the differential side gears and thrust washers into the differential case. If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.
4. Install the differential pinion gears and pinion gear thrust washers by performing the following steps: Position one pinion gear between the differential side gears. Position the second pinion gear between the differential side gears directly opposite the of the first gear. Rotate the differential side gears until the pinion gears is directly opposite the opening in the differential case. Install the thrust washers. Rotate the pinion gears toward the differential opening in order to permit the sliding in of the thrust washers.
5. Install the pinion shaft. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
6. For the 8.6 inch and 9.75 inch axles, install a new pinion shaft lock bolt. Tighten For the 8.6 inch axle, tighten the new pinion shaft lock bolt to 36 N.m (27 lb ft). For the 9.75 inch axle, tighten the new pinion shaft lock bolt to 27 N.m (20 lb ft).
7. For the 10.5 inch axle, install a new pinion shaft lock pin using a hammer and a drift pin. Important : The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.
8. Install the ring gear to the differential case. Important : The ring gear bolts on the 8.6 inch axle have left-hand threads. The ring gear bolts on the 9.75 inch and 10.5 inch axles have right-hand threads
9. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
10. Tighten the ring gear bolts. Tighten the bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N.m (89 lb ft). For the 9.75 inch and 10.5 inch axles, tighten the ring gear bolts in sequence to 177 N.m (131 lb ft).
11. Install the differential side bearings. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .

Bearings Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

Important : The differential bearings and the bearing cups are matched sets. Replace both the bearing and the cup when either part requires replacement.

1. Lubricate the bearings with axle lubricant. Inspect the bearings for smooth rotation.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for wear, cracks, brinelling, and scoring.

Differential Inspection

1. Check the pinion gear shaft for unusual wear.
2. Check the pinion and the side gear teeth for wear, cracks, scoring and spalling.
3. Check the thrust washers for wear.
4. Check the fit of the side gears in the differential case and on the axle shafts.
5. Check the differential case for cracks and scoring and replace all of the worn parts as necessary.

Pinion and Ring Gear Inspection

Ring and pinion gears are matched sets. When replacement of one or the other is necessary, both the ring and pinion gear must be replaced.

1. Check the pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear.
2. Check the pinion gear splines for wear.
3. Check the pinion flange/yoke splines for wear.
4. Check the fit of the pinion gear splines on the pinion flange/yoke.
5. Check the sealing surface of the pinion flange/yoke for nicks, burrs or rough tool marks that could damage the seal and cause an oil leak.
6. Check for worn or broken parts and replace as necessary.

Rear Axle Housing Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

1. Inspect for nicks or burrs that could prevent the outer diameter of the pinion seal from sealing. Remove any burrs.
2. Inspect the bearing cup bores for nicks or burrs. Remove any burrs that are found.
3. Inspect the housing for cracks. Replace the housing if any cracks are found.
4. Inspect the housing for foreign material such as metal chips, dirt, or rust.

Shims Inspection

Important

1. Do not reinstall the original cast iron production shims, if removed. Once the cast iron shims are removed from the axle housing, they must be replaced with service shims and spacers.
2. If service shims were previously installed, the shims can be reused.

Inspect the shims for cracks and chips. Replace the damaged shims.

Pinion Depth Adjustment (8.6 Inch Axle)

Tools Required

1. J 34925 Pinion Setting Gage and Components
2. J 8001 Dial Indicator Set

Important : Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

1. Lubricate the pinion bearings with axle lubricant.
2. Install the pinion bearings into the axle housing.
3. Assemble the J 21777-35 (1), the J 21777-43 (2), the J 21777-42 (3), and the J 21777-29 (4) into the axle housing as shown.
4. While holding the J 21777-43 stationary, install an inch-pound torque wrench on the nut of the J 21777-43 and tighten the nut until a rotating torque of 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.1-2.3 N.m (10-20 lb in) for used bearings is obtained. Rotate the assembly several times in both directions in order to seat the pinion bearings.
5. Check the rotating torque of the assembly. If the torque is less than 1.7 N.m (15 lb in) for new bearings or 1.1 N.m (10 lb in) for used bearings, continue to tighten the nut on the J 21777-43 until a rotating torque of 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.1-2.3 N.m (10-20 lb in) for used bearings is obtained.
6. Assemble the J 21777-45 (1, 2) to the J 21777-1 (3) into the differential side bearing bore of the axle housing as shown.
7. Install the differential bearing caps. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
8. Install the differential bearing cap bolts. Tighten the differential bearing cap bolts to 75 N.m (55 lb ft).
9. Rotate the J 21777-1 within the J 21777-45. The J 21777-1 must rotate back and forth freely within the discs. If the J 21777-1 does not rotate freely, disassemble the components, inspect for proper seating and/or misaligned components and reassemble.
10. Align the plunger of the J 21777-1 (1) to the 8.5 in gage block setting of the J 21777-29 (2).
11. Install the J 8001 to the J 21777-1 as follows: Loosely clamp the J 8001 onto the stem on the J 21777-1. Place the contact pad of the J 8001 onto the mounting post of the J 21777-1. With the contact pad of the J 8001 touching the mounting post of the J 21777-1, loosen the lock nut on the J 8001 and push down on the J 8001 until the needle the J 8001 has turned 3/4 of a turn clockwise. Tighten the clamp on the J 8001 finger tight.
12. Move the plunger of the J 21777-1 back and forth until the needle of the J 8001 indicates the greatest deflection. The deflection is the point where the needle changes direction.
13. At the greatest point of deflection, move the housing of the J 8001 until the needle indicates zero.
14. Move the plunger of the J 21777-1 back and forth again to verify the zero setting. Adjust the housing of the J 8001 as necessary to set the needle to zero.
15. Rotate the plunger of the J 21777-1 away from the J 21777-29 .
16. The value indicated on the J 8001 is the thickness of the shim needed in order to set the depth of the pinion.
17. Select the shim that indicates the proper thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
18. Remove the pinion depth setting tools.
19. Remove the pinion bearings.
20. Install the pinion shim between the pinion gear and the inner pinion bearing. Refer to «Drive Pinion Bearings Replacement (8.6 inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-86-inch) or «Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-bearings-replacement-975-inch) .

Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)

Tools Required

1. J 22536 Pinion Driver
2. J 24433 Pinion Cone and Side Bearing Installer
3. J 34925 Pinion Setting Gage and Components
4. J 45692 Pinion Shim Selector Kit - Dana Axles
5. J 45710 Pinion Bearing Oil Seal Installer
6. J 8001 Dial Indicator Set
7. J 8614-01 Flange and Pulley Holding Tool

Important : Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

1. Lubricate the pinion bearings with axle lubricant.
2. Assemble the J 45692-5 (2) and the outer pinion bearing onto the J 21777-43 (1) as shown.
3. Install the J 45692-5, the outer pinion bearing, and the J 21777-43 into the axle housing.
4. Install the inner pinion bearing into the axle housing.
5. Install the J 21777-35, 9.75 inch axle, or the J 45692-3, 10.5 inch axle, into the inner pinion bearing as shown.
6. Install the J 45692-1 into the axle housing as shown.
7. While holding the J 21777-43 stationary, tighten the nut on the J 21777-43 just until the end play between the pinion bearings is removed.
8. Rotate the assembly several times in both directions in order to seat the pinion bearings.
9. Measure the rotating torque of the assembly using an inch-pound torque wrench. Specification The rotating torque of the assembly should be between 2.3-5.1 N.m (20-45 lb in).
10. If the rotating torque of the assembly is less than 2.3 N.m (20 lb in), continue to tighten the nut of the J 21777-43 until a rotating torque of 2.3-5.1 N.m (20-45 lb in) is obtained.
11. Assemble the J 45692-2 (1) and the J 21777-1 (2) as shown.
12. Install the J 45692-2 (1) and the J 21777-1 (2) into the axle housing. Place the stem of the J 21777-1 onto the bottom step of the J 45692-1 for the 9.75 inch axle, the middle step for the 10.5 inch axle. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important : Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.
13. Install the bearing caps and bearing cap bolts. Tighten Tighten the bearing cap bolts to 109 N.m (80 lb ft).
14. Rotate the J 21777-1 within the J 45692-2. The J 21777-1 must rotate back and forth freely with the discs. If the J 21777-1 does not rotate freely, disassemble the components, inspect for proper seating and/or misaligned components and reassemble.
15. Install the J 8001 to the J 21777-1 as follows: Loosely clamp the J 8001 onto the stem on the J 21777-1. Place the contact pad of the J 8001 onto the mounting post of the J 21777-1. With the contact pad of the J 8001 touching the mounting post of the J 21777-1, loosen the lock nut on the J 8001 and push down on the J 8001 until the needle the J 8001 has turned 3/4 of a turn clockwise. Tighten the clamp on the J 8001 finger tight.
16. Move the plunger of the J 21777-1 (1) back and forth on the bottom step, 9.75 inch axle, or the middle step, 10.5 inch axle, of the J 45692-1 (2) until the needle of the J 8001 indicates the greatest deflection. The deflection is the point where the needle changes direction.
17. At the greatest point of deflection, move the indicator housing of the J 8001 until the needle indicates ZERO.
18. Move the plunger of the J 21777-1 back and forth again to verify the ZERO setting. Adjust the housing of the J 8001 as necessary to set the needle to ZERO.
19. Rotate the plunger of the J 21777-1 (1) away from the J 45692-1 (2). The value indicated is the amount of pinion shim thickness required for a nominal pinion setting.
20. In order to adjust the pinion shim thickness for the drive pinion that is to be installed, do the following: Read the number on the button end of the pinion. If the number on the button end of the pinion is "0", no adjustment of the pinion preload shim pack is necessary. If the number is not "0", the number will also have a corresponding "+" or "-" in front of it. The "+" or "-" indicates the amount of pinion preload shim thickness that either needs to be added to or subtracted from the amount determined in step 19 in order to the drive pinion gear to be positioned properly within the axle housing. For example, if the number on the button end of the pinion is a "+3", this indicates that 0.0762 mm (0.003 in) of shim thickness will need to be subtracted from the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table. If the number on the button end of the pinion is a "-3", this indicates that 0.0762 mm (0.003 in) of shim thickness will need to be added to the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table.
21. Remove the pinion depth setting tools.
22. Remove the pinion bearings.
23. Install the pinion position shim onto the drive pinion. Measure the thickness of the shim with a micrometer in order to verify the thickness.
24. Install the inner pinion bearing onto the drive pinion using the J 24433 .
25. Install the pinion bearing preload spacer (1) onto the drive pinion, 10.5 inch axle only.
26. Install the original pinion preload shims (2) onto the drive pinion. If the original shims are not available, assemble 1.52 mm (0.060 in) of pinion preload shims to install. Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.
27. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
28. Install the outer pinion bearing.
29. Install the thrust washer.
30. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
31. Install the washer.
32. Install the pinion yoke nut. Tighten Tighten the pinion yoke nut to 252 N.m (186 lb ft).
33. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Specification The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).
34. If the rotating torque of the drive pinion is not within specifications, adjust the pinion preload shim thickness by doing the following: Install the J 8614-01 to the pinion yoke. Remove the pinion nut while holding the J 8614-01 . Remove the washer. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Remove the thrust washer. Install the J 22536 . Ensure that the J 22536 is firmly seated on the drive pinion. Drive the pinion out using the J 22536 and a hammer. Remove the outer pinion bearing. Remove the pinion preload shim(s). Adjust the amount of pinion preload shim thickness by doing the following: Important : Removing approximately 0.0254 mm (0.001 in) of shim thickness will increase the rotating torque by approximately 71-89 N.m (8-10 lb in). If the rotating torque is too low, remove the appropriate amount of shim thickness from the shim thickness pack using the guideline above. Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size. Important : Adding approximately 0.0254 mm (0.001 in) of shim thickness will decrease the rotating torque by approximately 71-89 N.m (8-10 lb in). If the rotating torque is too high, add the appropriate amount of shim thickness to the shim thickness pack using the guideline above. Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.
35. Install the new pinion preload shim pack onto the drive pinion.
36. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
37. Install the outer pinion bearing.
38. Install the thrust washer.
39. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
40. Install the washer.
41. Install the pinion yoke nut. Tighten Tighten the pinion yoke nut to 252 N.m (186 lb ft).
42. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Specification The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).
43. If the rotating torque of the drive pinion is not within specification, adjust the pinion bearing preload shim pack as necessary following the steps above.
44. If the rotating torque is within specifications, install the J 8614-01 to the pinion yoke.
45. Remove the pinion nut while holding the J 8614-01 .
46. Remove the washer.
47. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown.
48. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1).
49. Install the new pinion oil seal using the J 45710 .
50. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
51. Install the washer.
52. Install the new pinion yoke nut. Tighten Tighten the pinion yoke nut to 339 N.m (250 lb ft).
53. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

Specification

The rotating torque of the drive pinion should be between 2.3-5.1 N.m (20-45 lb in).

Scheme 350

Differential Side Bearing Preload Adjustment (8.6 Inch Axle)

Tools Required

1. J 22779 Side Bearing Backlash Gage
2. J 25588 Side Bearing Shim Installer
3. J 25025 Guide Pins
4. J 8001 Dial Indicator Set

Important

1. The differential side bearing preload adjustment must be completed before the backlash adjustment can be started.
2. In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally.
3. Measure the service shims and the spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack.
4. Do not use or reuse the original cast iron production shims. Use service shims and spacers instead.

1. Install the drive pinion, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Specification The rotating torque of the drive pinion should be 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.1-2.3 N.m (10-20 lb in) for used bearings. Record the measurement. Important : Before installation of the differential assembly, ensure that the differential side bearing surfaces in the axle housing are clean and free of burrs. If the original differential side bearings are to be reused, the original differential side bearing cups must also be used.
3. Install the differential assembly with the differential side bearings and differential side bearing cups into the axle housing.
4. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing.
5. Side the differential assembly towards the service spacer in order to hold the spacer in place.
6. Install the J 22779 between the right side differential side bearing cup and the axle housing. Important : Overtightening may spread the housing and result in incorrect shim selection.
7. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved.
8. Remove the J 22779 .
9. Remove the service spacer.
10. Using a micrometer, measure the thickness of the J 22779 in 3 locations.
11. Calculate the average of the 3 measurements. Record the measurement.
12. Using a micrometer, measure the thickness of the service spacer. Record the measurement.
13. Add the thickness of the service spacer to the average thickness of the J 22779 . The resulting value is the total service shim thickness without preload for the axle.
14. Insert one 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing.
15. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the service shim.
16. Install the J 22779 on the left side of the differential assembly.
17. While rotating the ring gear back and forth, tighten the knob on the J 22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion.
18. Once the amount of backlash is obtained, remove the J 22779 .
19. Remove the differential case with the differential side bearings and the differential side bearing cups.
20. Remove the service shims.
21. Using a micrometer, measure the thickness of the J 22779 in 3 locations.
22. Calculate the average of the 3 measurements. This value is the left side service shim thickness without preload.
23. Subtract the service shim thickness for the left side of the axle, calculated in step 22, from the total service shim thickness, calculated in step 13. This value is the service shim thickness for the right side of the axle without preload.
24. In order to initially set the preload of the differential side bearings and the backlash to approximately 0.013-0.023 mm (0.005-0.009 in), take the value determined in step 23 and add 0.0203 mm (0.008 in) service shim thickness to this amount.
25. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 22. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
26. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of selective service shims equaling the thickness determined in step 24. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
27. Install the differential assembly with the differential side bearings and the differential side bearing cups.
28. Install the left side service spacer between the axle housing and the differential assembly.
29. Install the left side selective service shim or shims. The service shim or shims must be installed between the service spacer and the differential side bearing cup.
30. Install the right side service spacer between the axle housing and the differential assembly.
31. Install the right side selective service shim or shims using the J 25588 , if necessary. The service shim or shims must be installed between the service spacer and the differential side bearing cup. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
32. Install the differential bearing caps and the bolts. Tighten Tighten the differential bearing cap bolts to 75 N.m (55 lb ft).
33. Measure the drive pinion and differential side bearing preload using an inch-pound torque wrench. Rotate the pinion several times to ensure the differential side bearings have seated. Specification The rotating torque of the drive pinion and differential side bearings should be 3.9-6.2 N.m (30-55 lb in) for new bearings or 2.8-5.1 N.m (25-45 lb in) for used bearings. Record the measurement.
34. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 33. Multiply the value obtained by the axle ratio. Specification The differential side bearing preload should be 1.7-4.0 N.m (15-35 lb in).
35. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
36. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-86-inch-axle) or «Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-975-inch-105-inch) .
37. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection.»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection)

Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles)

Tools Required

J 24429 Side Bearing Backlash Spanner

Important : The rotating torque of the drive pinion must be within specifications before the differential case assembly can be installed.

Scheme 351

Scheme 352

1. Install the drive pinion, if necessary. Refer to «Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) or «Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__drive-pinion-and-ring-gear-replacement) .
2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Specification The rotating torque of the drive pinion should be 2.3-5.1 N.m (20-45 lb in). Record the measurement.
3. Install the differential side bearings, if necessary. Refer to «Differential Side Bearings Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__differential-side-bearings-replacement) .
4. Install the differential side bearing adjusters. Important : Before installation of the differential assembly, ensure that the differential side bearing surfaces in the axle housing are clean and free of burrs. If the original differential side bearings are to be reused, the original differential side bearing cups must also be used. If the differential case assembly cannot be installed, turn the differential side bearing adjuster into the axle housing until the proper clearance can be obtained.
5. Install the differential assembly.
6. Install the differential bearing caps.
7. Install the differential bearing cap bolts. Important : In the following service procedure, DO NOT torque the differential bearing cap bolts, only finger tighten them.
8. Install the differential bearing cap bolts. Important : DO NOT FORCE the ring gear into contact with the drive pinion.
9. Slide the differential case assembly towards the right side axle housing until the ring gear contacts the drive pinion. This is the ZERO backlash point. Important : If the ZERO backlash cannot be obtained, turn the right side differential bearing adjuster in towards the axle housing until the ring gear fully contacts the pinion to obtain the ZERO backlash.
10. Check for ZERO backlash.
11. While holding the ring gear against the pinion, turn the left differential bearing adjuster out from the axle housing using the J 24429 until it contacts the differential side bearing.
12. Turn the right differential bearing adjuster out from the axle housing using the J 24429 until it contacts the differential side bearing.
13. Back off the left differential adjuster approximately 2 slots using the J 24429 in order to obtain the initial backlash adjustment.
14. Using the J 24429 , tighten the right differential bearing adjuster until the differential case is in contact with the left differential adjuster.
15. Using the J 24429 , tighten the left and the right differential bearing adjuster one additional slot.
16. Rotate the pinion several times in order to seat the bearings.
17. Measure the drive pinion and differential case side bearing preload using an inch-pound torque wrench. Specification The rotating torque of the drive pinion and differential case bearings should be 4.0-6.4 N.m (35-57 lb in).
18. If the rotating torque of the drive pinion and differential case is less than 4.0 N.m (35 lb in), continue tighten the left and the right differential side bearing adjuster one slot at a time using the J 24429 until correct rotating torque is obtained.
19. If the rotating torque of the drive pinion and differential case is greater than 6.4 N.m (57 lb in), loosen the left and the right differential side bearing adjuster one slot at a time using the J 24429 until correct rotating torque is obtained.
20. Measure the drive pinion to ring gear backlash and adjust, if necessary. Refer to «Backlash Adjustment (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-86-inch-axle) or «Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__backlash-adjustment-975-inch-105-inch) .
21. Once the backlash is within specifications, measure the rotating torque of the drive pinion to verify that the rotating torque of the drive pinion and differential case is within specifications. If the rotating torque of the drive pinion and differential case is not within specifications, adjust the differential side bearing preload following the steps above. It may be necessary to repeat the differential side bearing preload and backlash adjustment procedures several times until both are within specifications. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
22. Tighten the differential bearing cap bolts. Tighten Tighten the differential bearing cap bolts to 109 N.m (80 lb ft).
23. Install the differential bearing adjuster locks.
24. Install the differential bearing adjuster lock bolts.

Tighten

Tighten the differential bearing adjuster lock bolts to 13 N.m (10 lb ft).

Scheme 353

Preliminary Inspection

Important : Ensure the brakes are fully released and do not drag.

Pull or push the tire at the top back and forth in order to test the wheel bearing play.

1. Use a pry bar under the tire as an alternative.
2. If the wheel bearing adjustment is correct, the movement will be barely noticeable.
3. If the movement is excessive, adjust the bearings.

Adjustment Procedure

Tools Required

J 2222-C Wheel Bearing Nut Wrench

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

1. Raise the vehicle.
2. Remove the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
3. Remove the hub adjuster nut retaining ring.
4. Remove the adjuster nut lock key. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
5. Tighten the wheel bearing adjusting nut using the J 2222-C . Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten Tighten the adjusting nut to 70 N.m (52 lb ft).
6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C .
7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight.
8. Insert the adjusting nut lock key into the keyway using one of the following procedures: If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important : Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key.
9. Install the retaining ring.
10. Install the axle shaft. Refer to «Rear Axle Shaft and/or Gasket Replacement»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
11. Inspect the lubricant level and add, if necessary. Refer to «Lubricant Level Inspection - Rear Drive Axle (8.6 Inch Axle)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) or «Lubricant Level Inspection - Rear Drive Axle (9.75 Inch, 10.5 Inch Axles)»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle) .
12. Lower the vehicle.

Backlash Adjustment (8.6 Inch Axle)

Tools Required

1. J 8001 Dial Indicator Set
2. J 25025 Guide Pins
3. J 25588 Side Bearing Shim Installer

Scheme 359

Scheme 360

1. Install the J 25025-1 and the J 8001 to the axle housing as shown.
2. Place the indicator stem of the J 8001-3 at the heel end of a gear tooth.
3. Set the J 8001-3 so that the stem is aligned with the gear rotation and perpendicular to the tooth angle.
4. Preload the dial of the J 8001-3 . Align the needle and the dial face of the J 8001-3 to ZERO.
5. While holding the drive pinion stationary, move the ring gear back and forth. Measure and record the backlash.
6. Repeat the measuring procedure at eight points around the ring gear. Specification The difference between the backlash at all of the measuring points should not vary by more than 0.05 mm (0.002 in).
7. If the difference between the backlash at all of the measuring points varies by more than 0.05 mm (0.002 in), inspect for the following conditions: Burrs A distorted case flange Uneven bolting
8. If the difference between all the measuring points is within specifications, the backlash at the minimum lash point measured should be: Specification The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in). Important: Do not use the original cast iron production shims to adjust the backlash. Use service shims and spacers instead. Adjust the thickness of the shim pack on each side of the differential in equal amounts. This will maintain the correct differential side bearing preload. Moving 0.05 mm (0.002 in) of shim thickness from one side of the differential to the other will change the backlash adjustment approximately 0.03 mm (0.001 in).
9. If the backlash is too small, increase the backlash using the following procedure: Remove the differential bearing cap bolts and the differential bearing caps. Mark the differential bearing caps left or right. Remove the differential assembly with the differential bearing cups and the shims. Mark the differential bearing cups and the shims left or right. Measure the thickness of left side shim pack. Measure the production shim or the shim and service spacer in 3 locations. Measure each shim separately. Calculate the average of the 3 measurements for each shim. Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the left side shim pack. Assemble a new left side shim pack by decreasing the appropriate amount of thickness from the original left side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), remove 0.10 mm (0.004 in) of thickness from the left side shim pack. Measure the thickness of right side shim pack. Measure the shim or the shim and service spacer in 3 locations. Measure each shim separately. Calculate the average of the 3 measurements for each shim. Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the right side shim pack. Assemble a new right side shim pack by increasing the appropriate amount of thickness to the original right side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), add 0.10 mm (0.004 in) of thickness to the right side shim pack.
10. If the backlash is too large, decrease the backlash using the following procedure: Remove the differential bearing cap bolts and the differential bearing caps. Mark the differential bearing caps left or right. Remove the differential assembly with the differential bearing cups and the shims. Mark the differential bearing cups and the shims left or right. Measure the thickness of left side shim pack. Measure the production shim or the shim and service spacer in 3 locations. Measure each shim separately. Calculate the average of the 3 measurements for each shim. Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the left side shim pack. Assemble a new left side shim pack by increasing the appropriate amount of thickness to the original left side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to increase the backlash by 0.05 mm (0.002 in), add 0.10 mm (0.004 in) of thickness to the left side shim pack. Measure the thickness of right side shim pack. Measure the shim or the shim and service spacer in 3 locations. Measure each shim separately. Calculate the average of the 3 measurements for each shim. Add the average of each of the shim measurements together. Record the measurement. This is the thickness for the right side shim pack. Assemble a new right side shim pack by decreasing the appropriate amount of thickness to the original right side shim pack. If the original shim is cast iron production shim, assemble the shim pack using a service spacer and service shims. For example, to decrease the backlash by 0.05 mm (0.002 in), remove 0.10 mm (0.004 in) of thickness to the right side shim pack.
11. Install the differential assembly with the differential bearing cups.
12. Install the left side service spacer between the axle housing and the differential case.
13. Install the right side service spacer between the axle housing and the differential case.
14. Install the left side service shim or shims using the J 25588 , if necessary. The service shim or shims must be installed between the service spacer and the differential bearing cup.
15. Install the right side service shim or shims using the J 25588, if necessary. The service shim or shims must be installed between the service spacer and the differential bearing cup. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
16. Install the differential bearing caps and bolts. Tighten Tighten the bolts to 75 N.m (55 lb ft).
17. Recheck the backlash and adjust, if necessary.
18. Once backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)

Tools Required

1. J 8001 Dial Indicator Set
2. J 24429 Side Bearing Backlash Spanner
3. J 25025 Guide Pins

Scheme 361

1. Install the J 25025-1 and the J 8001 to the axle housing as shown.
2. Place the indicator stem of the J 8001-3 at the heel end of a gear tooth.
3. Set the J 8001-3 so that the stem is aligned with the gear rotation and perpendicular to the tooth angle.
4. Preload the dial of the J 8001-3 . Align the needle and the dial face of the J 8001-3 to ZERO.
5. While holding the drive pinion stationary, move the ring gear back and forth. Measure and record the backlash.
6. Repeat the measuring procedure at eight points around the ring gear. Specification The difference between the backlash at all of the measuring points should not vary by more than 0.05 mm (0.002 in).
7. If the difference between the backlash at all of the measuring points varies by more than 0.05 mm (0.002 in), inspect for the following conditions: Burrs A distorted case flange Uneven bolting
8. If the difference between all the measuring points is within specifications, the backlash at the minimum lash point measured should be: Specification The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred backlash of 0.13-0.18 mm (0.005-0.007 in).
9. If the backlash is too small, increase the backlash by turning the left differential bearing adjuster in one slot and the right differential bearing adjuster out one slot using the J 24429 until the correct backlash is obtained.
10. If the backlash is too large, decrease the backlash by turning the right differential bearing adjuster in one slot and the left differential bearing adjuster out one slot using the J 24429 until the correct backlash is obtained.
11. Recheck the backlash following the steps above to verify that the backlash is within specifications. CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
12. Tighten the differential bearing caps and bolts. Tighten Tighten the bolts to 109 N.m (80 lb ft).
13. Recheck the backlash and adjust, if necessary.
14. Once backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/chevy-express-h2500/2003-2003/remont/differentials-drive-axles/#rear-drive-axle__gear-tooth-contact-pattern-inspection) .

Gear Tooth Contact Pattern Inspection

The gear contact pattern check is not a substitute for adjusting the pinion depth and backlash. Use this method in order to verify the correct running position of the ring gear and the drive pinion. Gear sets which are not positioned properly may be noisy and/or have a short life span. A pattern check ensures that when best contact has been obtained between the ring gear and the drive pinion, the system will produce low noise and have a long life.

Drive Pinion and Ring Gear Identification

Production drive pinion and ring gears are manufactured by using a 2-cut or a 5-cut method. The 2-cut drive pinions and ring gears can be identified by having a groove cut into the outside edge of the ring gear and a ring on the stem of the drive pinion. The gear tooth contact patterns that are produced from each style of gear set differ slightly. A 2-cut gear will produce a pattern that is bias from the toe to the heel of the tooth (drive side), while a 5-cut gear set will produce a square pattern from the toe to the heel of the tooth (drive side). When diagnosing the gear tooth contact pattern, regardless of what type of gear set it is, a correct pattern will be centered within the area of the tooth, from toe to heel and from top to bottom.

Gear Tooth Nomenclature

The side of the ring gear tooth which curves outward, or is convex, is the drive side (4). The concave side is the coast side (3). The end of the tooth nearest the center of the ring gear is the toe end (2). The end of the tooth farthest away from the center is the heel end (1).

Scheme 362

Adjustments Affecting Tooth Contact

The following 2 adjustments affect the tooth contact pattern

1. Backlash adjustment
2. Pinion depth adjustment

The effects of bearing preloads are not readily apparent on hand-loaded tooth contact pattern tests. However, bearing preloads should be within specifications before proceeding with backlash and pinion depth adjustments.

Backlash Adjustment

The backlash can be adjusted by either varying the thickness of the side bearing shims from side to side or by moving the adjuster sleeve(s) in or out, or both. By adjusting the shim thickness or moving the adjuster sleeve(s), the case and ring gear assembly will move closer to or further away from the pinion. In most cases, adjusting the backlash will correct an abnormal contact pattern. This adjustment will also be used to set the side bearing preload.

1. If the thickness of the right shim is increased or the adjuster sleeve is moved in (if applicable), along with an equal decrease in the thickness of the left shim or the adjuster sleeve is moved out (if applicable), the backlash will increase.
2. If the thickness of the left shim is increased or the adjuster sleeve is moved in (if applicable), along with an equal decrease in the thickness of the right shim or the adjuster sleeve is moved out (if applicable), the backlash will decrease.

Pinion Depth Adjustment

Adjust the position of the pinion by increasing or decreasing the distance between the pinion head and the centerline of the ring gear. Decreasing the distance moves the pinion closer to the centerline of the ring gear. Increasing the distance moves the pinion farther away from the centerline of the ring gear.

Scheme 363

1. Wipe clean the differential case, the ring gear and the axle housing of lubricant. Carefully clean each tooth of the ring gear.
2. Use a medium stiff brush in order to sparingly apply gear marking compound, GM P/N 1052351 (Canadian P/N 10953497) or equivalent, to all of the ring gear teeth.
3. Torque the bearing caps bolts to specification. Important: Performing a test without loading the gears will not produce a satisfactory pattern.
4. Apply the park brake until a torque load of 14 N.m (10 lb ft) is required in order to turn the pinion. Important: Avoid turning the ring gear excessively.
5. Using a wrench, turn the drive pinion flange/yoke so that the ring gear rotates 3 full revolutions.
6. Turn the drive pinion flange/yoke in the opposite direction so that the ring gear rotates 3 full revolutions in the opposite direction.
7. Observe the pattern on the ring gear teeth. Compare the pattern with the following illustrations.

Condition

The backlash and pinion depth is correct.

Correction

None required.

Service Hints

Loose bearings on the drive pinion or in the differential case may cause patterns that vary. If the contact pattern varies, inspect the following preload settings

1. Total assembly
2. Differential case
3. Pinion

If these settings are correct, inspect for damage or incorrectly assembled parts.

Scheme 364

The backlash is incorrect. The ring gear is too far away from the pinion.

Decrease the backlash. Move the ring gear closer to the pinion by adjusting the side bearing shim thickness or the adjuster sleeve(s). Refer to Backlash Adjustment (8.6 Inch Axle) or Backlash Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 365

The backlash is incorrect. The ring gear is too close to the drive pinion.

Increase the backlash. Move the ring gear away from the pinion by adjusting the side bearing shim thickness or the adjuster sleeve(s). Refer to Backlash Adjustment (8.6 Inch Axle) or Backlash Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 366

The backlash is incorrect. The ring gear is too far away from the pinion.

Decrease the backlash. Move the ring gear closer to the pinion by adjusting the side bearing shim thickness or the adjuster sleeve(s). Refer to Backlash Adjustment (8.6 Inch Axle) or Backlash Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 367

The backlash is incorrect. The ring gear is too close to the drive pinion.

Increase the backlash. Move the ring gear away from the pinion by adjusting the side bearing shim thickness or the adjuster sleeve(s). Refer to Backlash Adjustment (8.6 Inch Axle) or Backlash Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 368

The pinion depth is incorrect. The pinion gear is too far away from the ring gear.

Increase the pinion depth. Move the pinion gear closer to the ring gear by increasing the pinion shim thickness. Refer to Pinion Depth Adjustment (8.6 Inch Axle) or Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 369

The pinion depth is incorrect. The pinion gear is too close to the ring gear.

Decrease the pinion depth. Move the pinion gear away from the ring gear by decreasing the pinion shim thickness. Refer to Pinion Depth Adjustment (8.6 Inch Axle) or Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles) .

Scheme 370

Rear axles for this vehicle consist of the following components

1. Differential axle housing
2. Differential carrier
3. Right and left axle tubes
4. Right and left axle shafts

These axles are either full-floating or semi-floating. These axles can be identified as follows: the semi-floating axle has axle shafts with C-clips inside the differential carrier on the inner ends of the axle shafts. The full-floating axle has bolts at the hub retaining the axle shafts to the hub assembly. The axles can be identified by the stamping on the right side axle tube and may also be identified by the ring gear size. The ring gear sizes include 8.60, 9.50, and 10.50 inch axles. The locking differential information for these rear axles can be located in the locking differential section.

The driveline components in this vehicle have been system balanced at the factory. System balance provides for a smoother running driveline. These components include the propeller shafts, drive axles, pinion shafts and output shafts. Affixed to the rear axle is a system balanced driveline notice indicating that the driveline components have been factory tested. All components must be referenced marked before disassembly and reassembly in the exact relationship to each other the components had before removal.

An open differential has a set of four gears. Two are side gears and two are pinion gears. Some differentials have more than two pinion gears. Each side gear is splined to an axle shaft which turns when it's side gear rotates. The pinion gears are mounted on a differential pinion shaft, and the gears are free to rotate on this shaft. The pinion shaft is fitted into a bore in the differential case and is at right angles to the axle shafts.

Power is transmitted through the differential as follows: the drive pinion rotates the ring gear. The ring gear, which is bolted to the differential case, rotates the case. The differential pinion, as it rotates the case, forces the pinion gears against the side gears. When both wheels have equal traction, the pinion gears do not rotate on the pinion shaft because the input force on the pinion gear is equally divided between the two side gears. Therefore, the pinion gears revolve with the pinion shaft, but do not rotate around the shaft itself. The side gears, being splined to the axle shafts and in mesh with the pinion gears rotate the axle shafts. If a vehicle were always driven in a straight line, the ring and pinion gears would be sufficient. The axle shaft could be solidly attached to the ring gear and both driving wheels would turn at equal speed. However, if it became necessary to turn a corner, the tires would scuff and slide because the differential allows the axle shafts to rotate at different speeds. When the vehicle turns a corner, the inner wheel turns slower than the outer wheel and slows it's rear axle side gear because the shaft is splined to the side gear. The rear axle pinion gears will roll around the slowed rear axle side gear, driving the rear axle side gear wheel faster.

Scheme 371

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Scheme 375

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Scheme 379

Scheme 380

See also:
• TIRE AND WHEEL REMOVAL AND INSTALLATION
• BRAKE CALIPERS
• PROPELLER SHAFT REPLACEMENT - ONE PIECE
• SHOCK ABSORBER REPLACEMENT
• BRAKE CALIPER BRACKETS
• Symptoms - Rear Drive Axle
• Differential Replacement (9.75 Inch, 10.5 Inch Axles)
• Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)
• Drive Pinion Bearings Replacement (8.6 inch Axle)
• Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)
• Pinion Depth Adjustment (8.6 Inch Axle)
• Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)
• Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)
• Differential Side Bearings Replacement
• Differential Side Bearing Preload Adjustment (8.6 Inch Axle)
• Differential Side Bearing Preload Adjustment (9.75 Inch, 10.5 Inch Axles)
• Backlash Adjustment (8.6 Inch Axle)
• Backlash Adjustment (9.75 Inch, 10.5 Inch Axles)
• Gear Tooth Contact Pattern Inspection
• Rear Axle Hub, Bearing, Cup, and/or Seal Replacement
• Rear Axle Shaft Seal and/or Bearing Replacement