Front Drive Axle Chevrolet Express G2500

Axle Preload and Backlash Specifications

Axle Preload and Backlash Specifications

Adhesives, Fluids, Lubricants, and Sealers

Adhesives, Fluids, Lubricants, and Sealers

Scheme 49

Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system functions. Refer to Front Drive Axle Description and Operation .

Noise Diagnosis

Any gear-driven unit produces a certain amount of noise that is normal and that conventional repairs or adjustment cannot eliminate. Slight noise that is heard only at a certain speed or under unusual or remote conditions is acceptable. For example, this noise tends to reach a peak at speeds from 60-100 km/h (40-60 mph) depending upon road and load conditions, or upon gear ratio and tire size. Noise of this kind does not indicate trouble in the axle assembly.

When an axle is suspected of being noisy, make a thorough test in order to determine whether the noise originates in the tires, road surface, wheel bearings, engine, transmission, propeller shaft, or axle assembly.

Classifying the Symptom

Front Drive Axle symptoms can usually be classified into the following categories

1. Leaks
2. Noises
3. Vibrations

Leak and noise related symptoms are diagnosed within the Front Drive Axle section. For vibration related symptoms, refer to Vibration Diagnosis, Starting Point, and Correction .

Visual/Physical Inspection

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

Symptoms List

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

1. «Front Drive Axle Noises»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle)
2. «Noisy in Drive»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__noisy-in-drive)
3. «Noisy When Coasting»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__noisy-when-coasting)
4. «Intermittent Noise»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__intermittent-noise)
5. «Constant Noise»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__constant-noise)
6. «Noisy on Turns»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__noisy-on-turns)
7. «Front Axle Lubricant Leak Diagnosis»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__front-axle-lubricant-leak-diagnosis)

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 ring and pinion gear replacement or adjustment, depending on the mileage of the gear set.

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 front axle side bearing. This noise can be confused with front wheel bearing noise. Inspect and replace the bearings and the affected components as required.

Front Wheel Bearing Noise

A rough front 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) wheel bearing can be heard by spinning the 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 the differential case assembly 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.

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 ring and pinion gear replacement or adjustment, depending on the mileage of the gear set.

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 front axle side bearing. This noise can be confused with front wheel bearing noise. Inspect and replace the bearings and the affected components as required.

A rough front wheel bearing produces a noise which continues with the vehicle 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 and/or noisy wheel bearing can be heard by spinning the wheels by hand and listening at the hubs for the noise. Inspect and replace the bearings and the affected components as needed.

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

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.

Noisy in Drive

Noisy in Drive

Noisy When Coasting

Noisy When Coasting

Intermittent Noise

Intermittent Noise

Constant Noise

Constant Noise

Noisy on Turns

Noisy on Turns

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 50

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.

Scheme 51

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.

Scheme 52

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.

Scheme 53

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 54

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.

Scheme 55

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 56

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.

Scheme 57

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 58

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 59

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.

Scheme 60

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.

Scheme 61

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

Scheme 62

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.

Scheme 63

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

Scheme 64

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.

Scheme 65

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.

Scheme 66

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.

Scheme 67

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 68

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 69

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.

Scheme 70

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

Scheme 71

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

Scheme 72

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

Scheme 73

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.

Front Axle Lubricant Leak Diagnosis

Front axle lubricant leaks can occur at the following locations

1. Axle shaft oil seals
2. Differential carrier assembly mating surface
3. Drain plug
4. Fill plug
5. Inner axle tube assembly to differential carrier assembly mating surface
6. Pinion yoke oil seal
7. Vent tube and/or connector

Determining the Cause

While most front 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 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.

Sealing Surfaces

Front axles are assembled using specific sealers. A leak at a surface sealed with sealant is usually caused by a poor fit of the components but can also be caused by the use of the wrong sealant. When correcting a sealant leak, inspect each component for distortion and for nicks or gouges that may prohibit the sealant from sealing properly and when re-assembling the component, use the proper sealant.

Differential Carrier Assembly

Lubricant leaks at the differential carrier assembly can occur at the following locations

1. Drain plug
2. Fill plug
3. Vent tube

Drain and fill plug leaks are usually caused by a loose plug. A vent tube leak can be cause by a loose fitting vent hose or by a vent tube assembly whose interior shield is stuck in the upside down position. Inspect the vent plug's interior shield for unrestricted movement, repair or replace the plug as necessary. Drain or fill plug leaks can be repaired by either tightening the plug or by using an approved sealer on the threads on the plug.

Removal Procedure

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Clean the area around the front axle fill plug and the drain plug.
3. Remove the fill plug.
4. Remove the drain plug.
5. Drain the fluid from the front differential carrier assembly.

Installation Procedure

1. Install the drain plug and tighten to 33 N.m (24 lb ft).
2. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to «Approximate Fluid Capacities»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) , and «Fluid and Lubricant Recommendations»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
3. Install the fill plug and tighten to 33 N.m (24 lb ft).
4. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the vent hose from the frame.
3. Remove the vent hose from the front axle.

1. Install the vent hose to the front axle.
2. Install the vent hose to the frame.
3. Lower the vehicle.

Special Tools

1. J-2619-01 Slide Hammer
2. J-29369-1 Bushing and Bearing Remover
3. J-42738 Seal Installer

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Drain the front differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
3. Remove the front drive axle inner shaft and housing assembly. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
4. Remove the front drive axle inner shaft (1) from the inner shaft housing.
5. Mount the inner shaft housing in a vise.
6. Assemble the J-2619-01 Slide Hammer (1) and the J-29369-1 Bushing and Bearing Remover (2) to the inner shaft seal.
7. Using the J-2619-01 Slide Hammer with the J-29369-1 Bushing and Bearing Remover, remove the inner shaft seal (1) from the inner shaft housing.
8. Clean the inner shaft housing to differential housing sealing surface of any debris, lubricant, or sealer.

1. Using the J-42738 Seal Installer (1), install the inner shaft seal.
2. Apply sealant to the inner shaft housing to differential housing sealing surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__adhesives-fluids-lubricants-and-sealers) .
3. Carefully guide the front drive axle inner shaft (1) past the inner shaft seal and install the front drive axle inner shaft into the inner shaft housing.
4. Install the front drive axle inner shaft and housing assembly. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
5. Fill the front differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .

J-42738 Seal Installer

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Drain the front differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
3. Disconnect the wheel drive shaft inner joint from the front drive axle inner shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
4. Remove the front drive axle inner shaft (1).
5. Remove the inner shaft seal cover bolts (1).
6. Remove the inner shaft seal cover (1).
7. Remove the inner shaft seal (1).
8. Clean the inner shaft seal cover to differential housing sealing surface of any debris, lubricant, or sealer.

1. Position the inner shaft seal (1) to the inner shaft seal cover.
2. Using the J-42738 Seal Installer, install the inner shaft seal to the inner shaft seal cover.
3. Apply sealant to the inner shaft seal cover to differential housing sealing surface. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__adhesives-fluids-lubricants-and-sealers) .
4. Install the inner shaft seal cover (1).
5. Install the inner shaft seal cover bolts (1) and tighten to 18 (13 lb ft).
6. Carefully guide the front drive axle inner shaft (1) past the inner shaft seal until the retaining ring contacts the differential case side gear.
7. Using a soft-faced mallet, tap the front drive axle inner shaft into the differential case side gear until the retaining ring is fully seated.
8. Ensure the front drive axle inner shaft retaining ring is fully seated by attempting to pull the inner shaft from the differential case side gear.
9. Install the wheel drive shaft inner joint to the front drive axle inner shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
10. Fill the front differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Drain the differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
3. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
4. Disconnect the wheel drive shaft from the inner axle shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) . It is not necessary to remove the wheel drive shaft from the vehicle.
5. Place a pry bar between the inner axle shaft flange and the inner axle shaft housing.
6. Disconnect the inner axle shaft from the differential case side gear using the pry bar. Do not remove the inner axle shaft at this time.
7. Install a support jack underneath the differential carrier assembly.
8. Remove the upper inner shaft housing bushing bolt and nut.
9. Remove the lower inner shaft housing bushing bolt and nut.
10. Remove the inner axle shaft housing bolts from the differential carrier assembly.
11. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
12. Remove the inner axle shaft from the inner axle shaft housing.
13. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing. Refer to «Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .

1. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to «Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
2. Install the inner axle shaft into the inner axle housing. Do not install the inner axle shaft completely into the inner axle shaft housing at this time.
3. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
4. Install the inner axle shaft housing with the inner axle shaft to the differential carrier assembly.
5. Install the inner axle shaft housing bolts and tighten to 48 N.m (35 lb ft).
6. Install the lower inner axle shaft housing bushing bolt and nut.
7. Install the upper inner axle shaft housing bushing bolt and nut and tighten to 85 N.m (63 lb ft).
8. Remove the support jack.
9. Install the inner axle shaft into the differential case side gear by doing the following: Carefully guide the inner axle shaft through the inner axle housing until the retaining ring on the inner axle shaft contacts the differential case side gear. Install the inner axle shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
10. Install the wheel drive shaft to the inner axle shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
11. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
12. Lower the vehicle.

1. J 2619-01 Slide Hammer
2. J 8092 Universal Driver Handle - 3/4 in - 10
3. J 29369-1 Bushing and Bearing Remover
4. J 42211 Axle Bearing Installer
5. J 42738 Seal Installer

Scheme 74

Scheme 75

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Drain the differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
3. If replacing the left side seal, perform the following steps: Disconnect the wheel drive shaft from the inner shaft flange and set aside. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) . Remove the inner shaft. Remove the inner shaft seal cover bolts. Remove the inner shaft seal cover assembly.
4. If replacing the left side bearing, perform the following steps: Remove differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) . Remove the left inner shaft. Remove the inner shaft seal cover bolts. Remove the inner shaft seal cover assembly. Install the J 29369-1 Bushing and Bearing Remover to the backside of the inner shaft bearing. Install the J 2619-01 Slide Hammer to the J 29369-1 Bushing and Bearing Remover. Remove the inner shaft bearing by pulling on the J 2619-01 Slide Hammer.
5. If replacing the right side seal and/or bearing, perform the following steps: Remove the inner shaft and housing assembly. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) . Remove the inner shaft from the inner shaft housing. Install the inner shaft housing into a vise. Install the J 29369-1 Bushing and Bearing Remover (2) to the backside of the seal or bearing as necessary. Install the J 2619-01 Slide Hammer (1) to the J 29369-1 Bushing and Bearing Remover (2). Remove the seal or the seal and bearing by pulling on the J 2619-01 Slide Hammer.

Scheme 76

Scheme 77

1. If replacing the right side bearing, perform the following steps: Install the inner shaft housing into a vise. Install the bearing with the square shoulder in using the J 42211 Axle Bearing Installer (2) and the J 8092 Universal Driver Handle - 3/4 in - 10 (1).
2. If replacing the right side seal, perform the following steps: Install the inner shaft housing into a vise. Install the new inner shaft seal using the J 42738 Seal Installer. NOTE: Carefully guide the inner shaft through the oil seal as to not nick or cut the seal. Install the inner shaft into the inner shaft housing. Install the inner shaft and housing assembly. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
3. If installing the left side bearing, perform the following steps: Install the bearing with the square shoulder in using the J 42211 Axle Bearing Installer and the J 8092 Universal Driver Handle - 3/4 in - 10. Install the inner shaft seal cover assembly. CAUTION: Refer to «Fastener Caution»(/chevrolet/express-g2500/2013-2013/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) . Install the inner shaft seal cover bolts and tighten to 18 N.m (13 lb ft). Install the left inner shaft into the differential carrier assembly by performing the following steps: NOTE: Carefully guide the inner shaft through the oil seal as to not nick or cut the seal. Carefully guide the inner shaft through the oil seal until the retaining ring on the inner shaft contacts the differential case side gear. Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear. Install differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) . Install the wheel drive shaft to the inner shaft flange. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
4. Fill the differential carrier assembly with the proper fluid. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
5. Lower the vehicle.

1. J 33782 Pinion Oil Seal Installer
2. J 8614-01 Pinion Flange Holder

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake calipers. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
4. Reference mark the relationship of the propeller shaft to the front axle pinion yoke.
5. Remove the pinion yoke retainer bolts and the yoke retainers from the front axle pinion yoke.
6. Disconnect the propeller shaft from the front axle pinion yoke. Wrap the bearing cups with tape in order to prevent the loss of bearing rollers.
7. Support the propeller shaft and move out of the way as necessary.
8. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: The pinion bearings The pinion seal The carrier bearings The axle bearings The axle seals
9. Scribe an alignment line between the pinion shaft and the pinion yoke.
10. Install the J 8614-01 Pinion Flange Holder onto the pinion yoke as shown.
11. Remove the pinion nut while holding the J 8614-01 Pinion Flange Holder.
12. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 Pinion Flange Holder (3) as shown.
13. Remove the pinon yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 Pinion Flange Holder (3).
14. Remove the oil seal using a suitable seal removal tool.

1. Install the oil seal by doing the following: Position the oil seal in the bore. Install the J 33782 Pinion Oil Seal Installer over the oil seal. Strike the J 33782 Pinion Oil Seal Installer with a hammer until the seal flange seats on the axle housing surface.
2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke.
3. Install the pinion yoke. Align the reference marks made during removal.
4. Seat the pinion flange onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the flange.
5. Install the washer.
6. Install a new pinion nut.
7. Install the J 8614-01 Pinion Flange Holder onto the pinion flange as shown in the graphic.
8. Tighten the pinion nut while holding the J 8614-01 Pinion Flange Holder. Tighten the pinion 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 the measurement with the rotating torque recorded earlier. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 N.m (3-5 lb in) greater than the 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 to the pinion yoke. Align the reference marks made during removal.
12. Install the pinion yoke retainers and the bolts and tighten to 25 N.m (18 lb ft).
13. Inspect the axle lubricant level, and add, if necessary. Refer to «Front Axle Lubricant Level Inspection»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__front-axle-lubricant-level-inspection) .
14. Install the brake calipers. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
15. Install the tire and wheel assemblies. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
16. Lower the vehicle.

Tools Required

J 45850 Front Axle Bushing Remover/Installer

1. Remove the inner shaft housing. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
2. If replacing the upper inner shaft housing bushing, install the inner shaft housing into a vise.
3. Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the upper inner shaft housing bushing as shown.
4. Remove the upper inner shaft housing bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.
5. If replacing the lower inner shaft housing bushing, install the inner shaft housing into a vise so that the lower inner shaft bushing bore is flush with the jaws of the vise.
6. Install the J 45850-2 (2), J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the lower inner shaft housing bushing as shown.
7. Remove the lower inner shaft housing bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.

1. If replacing the lower inner shaft housing bushing, install the inner shaft housing bushing bore into a vise.
2. Place the lower inner shaft housing bushing over the bushing bore.
3. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown. Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.
4. Install the lower inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
5. If replacing the upper inner shaft housing bushing, install the inner shaft housing bushing bore into a vise.
6. Place the upper inner shaft housing bushing over the bushing bore.
7. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown. Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut.
8. Install the upper inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
9. Remove the inner shaft housing from the vise.
10. Install the inner shaft housing. Refer to «Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .

J 45850 Front Axle Bushing Remover/Installer

1. Remove the differential carrier assembly. It is not necessary to drain the differential carrier assembly. Seal the vent tube opening with a piece of tape to prevent the axle lubricant from leaking from the differential carrier assembly. Refer to «Differential Carrier Assembly Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
2. If replacing the upper differential carrier assembly bushing, remove the bushing by performing the following steps: Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown. Remove the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.
3. If replacing the lower differential carrier assembly bushing, remove the bushing by performing the following steps: Install the J 45850-2 (2), the J 45850-3 (1), the forcing screw, the thrust bearing, and the nuts (3) over the differential carrier assembly bushing as shown. Remove the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850 Front Axle Bushing Remover/Installer.

1. If replacing the lower differential carrier assembly bushing, install the bushing by performing the following steps: Install the differential carrier assembly bushing into the differential carrier assembly bushing bore. Install the J 45850-2 (3), the J 45850-3 (2), the forcing screw, the thrust bearing, and the nuts (1, 4-5) over the differential carrier assembly bushing as shown. Install the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850 Front Axle Bushing Remover/Installer.
2. If replacing the upper differential carrier assembly bushing, install the bushing by performing the following steps: Install the differential carrier assembly bushing into the differential carrier assembly bushing bore. Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown. Install the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.
3. Install the differential carrier assembly. Once the differential carrier assembly is installed, remove the piece of tape in order to connect the vent hose. Refer to «Differential Carrier Assembly Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Using a jack stand, support the rear axle.
3. Drain the fluid from the differential carrier assembly. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
4. Disconnect the propeller shaft from the differential carrier assembly. Refer to «Front Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) . Support the propeller shaft as necessary.
5. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Remove the front engine crossmember. Refer to «Engine Front Crossmember Replacement (RWD)»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) , «Engine Front Crossmember Replacement (4WD)»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Place a transmission jack under the differential carrier assembly. Secure and support the differential carrier assembly to the transmission jack.
8. Place an alignment mark between the wheel drive shafts and the inner shaft flanges.
9. Remove the wheel drive shaft to inner shaft bolts.
10. Disconnect the left side wheel drive shaft from the inner shaft.
11. Disconnect the right side wheel drive shaft from the inner shaft.
12. Disconnect the differential carrier assembly vent hose from the differential carrier assembly.
13. Remove the upper inner shaft housing mounting bolt.
14. Remove the upper differential carrier assembly mounting bolt.
15. Remove the differential carrier assembly.

1. Install the differential carrier assembly to the vehicle.
2. Connect the vent hose to the differential carrier assembly.
3. Install the differential carrier assembly upper mounting bolt and the nut. Do not tighten the bolt to specification at this time.
4. Install the inner shaft upper mounting bolt and the nut. Do not tighten the bolt to specification at this time.
5. Install the front engine crossmember. Refer to «Engine Front Crossmember Replacement (RWD)»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) , «Engine Front Crossmember Replacement (4WD)»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
6. Tighten the upper differential carrier assembly and inner shaft housing mounting bolts and tighten to 85 N.m (63 lb ft).
7. Connect the left side wheel drive shaft to the inner shaft flange. Align the marks made during removal.
8. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
9. Install the left side wheel drive shaft to inner shaft bolts and tighten to 50 N.m (37 lb ft).
10. Connect the right side wheel drive shaft to the inner shaft flange. Align the marks made during removal.
11. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.
12. Install the right side wheel drive shaft to inner shaft bolts and tighten to 50 N.m (37 lb ft).
13. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
14. Connect the propeller shaft to the differential carrier assembly. Refer to «Front Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
15. Fill the differential carrier assembly with the proper lubricant. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
16. Remove the jack or utility stands.
17. Lower the vehicle.
18. Inspect the vehicle's Z height and adjust, if necessary. Refer to «Trim Height Inspection»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#suspension-system-general-diagnosis) .

Front Axle Lubricant Level Inspection

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Inspect the front axle for leaks. Repair as necessary.
3. Clean the area around the front axle fill plug.
4. Remove the fill plug.
5. Inspect the oil level. Specification The oil level should be between 0-10 mm (0-0.38 in) below the bottom of the fill plug opening.
6. If the level is low, add oil until the level is even with the bottom of the edge of the fill plug opening. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
7. Install the fill plug and tighten to 33 N.m (24 lb ft).
8. Lower the vehicle.

Inspection Procedure

Perform the following before disassembling the axle

1. Remove the fill plug from the axle.
2. Remove the drain plug from the axle.
3. Drain the axle lubricant.
4. Inspect the oil and the case for metal chips. Determine the source of the metal chips, such as a broken gear or bearing cage.
5. Measure the rotating torque of the drive pinion and differential case assembly using an inch-pound torque wrench, if possible. Record the measurement.
6. Check the drive pinion to ring gear backlash, if possible.

This information can be used in order to determine the cause of the axle problem. The information will also help when setting up and preloading the differential case.

Determine the cause of the axle problem before disassembly, if possible.

Disassembly Procedure

Tools Required

1. J 2619-01 Slide Hammer
2. J 22912-B Pinion Bearing Remover
3. J 8092 Universal Driver Handle - 3/4 in - 10
4. J 8614-01 Flange and Pulley Holding Tool
5. J 29369-1 Bushing/Bearing Remover
6. J 45224 Side Bearing Adjuster
7. J 45228 Pinion Bearing Cup Remover/Installer
8. J 45232 Differential Bearing Adjuster Needle Bearing Installer - LH
9. J 45234 Pinion Remover - 7.25 in Axle
10. J 45850 Front Axle Bushing Remover/Installer

1. Remove the inner housing to differential carrier assembly bolts.
2. Remove the inner housing and inner shaft from the differential carrier assembly.
3. Remove the inner shaft.
4. Install the inner shaft housing into a vise.
5. Install the J 29369-1 Bushing/Bearing Remover (2) and the J 2619-01 Slide Hammer (1) behind the inner shaft bearing.
6. Remove the inner shaft bearing and inner shaft seal using the J 2619-01 Slide Hammer.
7. Install the J 45850-2 (2), J 45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the upper inner shaft housing bushing as shown.
8. Remove the upper inner shaft housing bushing using the J 45850 Front Axle Bushing Remover/Installer.
9. Remove the inner shaft housing from the vise.
10. Install the inner shaft housing into a vise so that the lower inner shaft bushing bore is flush with the jaws of the vise.
11. Install the J 45850-2 (2), J 45850-3 (1), the forcing screw, bearing, washers and nuts (1) over the lower inner shaft housing bushing as shown.
12. Remove the lower inner shaft housing bushing using the J 45850 Front Axle Bushing Remover/Installer.
13. Remove the inner shaft housing from the vise.
14. Install the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case.
15. Remove the left inner shaft using a hammer and a brass drift.
16. Remove the inner shaft seal cover bolts.
17. Remove the inner shaft seal cover.
18. Remove the left side differential bearing adjuster lock bolt.
19. Remove the left side differential bearing adjuster lock.
20. Remove the right side differential bearing adjuster lock bolt.
21. Remove the right side differential bearing adjuster lock.
22. Remove the differential carrier assembly from the vise.
23. Remove the differential carrier assembly bolts.
24. Separate the right carrier case half from the left carrier case half by tapping on the carrier case using a hammer and a brass drift.
25. Remove the differential case assembly.
26. Remove the left differential bearing adjuster by doing the following: Install the J 45224 Side Bearing Adjuster onto the differential bearing adjuster. Turn the J 45224 Side Bearing Adjuster counterclockwise in order to remove the differential bearing adjuster.
27. Remove the differential bearing cup.
28. Remove the right differential bearing adjuster by doing the following: Install the J 45224 Side Bearing Adjuster onto the differential bearing adjuster. Turn the J 45224 Side Bearing Adjuster counterclockwise in order to remove the differential bearing adjuster.
29. Remove the differential bearing cup.
30. Remove the left inner shaft bearing using the J 45232 Differential Bearing Adjuster Needle Bearing Installer - LH (2) and the J 8092 Universal Driver Handle - 3/4 in - 10 (1).
31. Install the J 8614-01 Flange and Pulley Holding Tool onto the pinion yoke as shown in the graphic. Remove the pinion nut while holding the J 8614-01 Flange and Pulley Holding Tool.
32. Remove the washer.
33. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 Flange and Pulley Holding Tool (1) as shown.
34. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 Flange and Pulley Holding Tool (1).
35. Install the J 45234 Pinion Remover - 7.25 in Axle onto the left differential carrier case and over the drive pinion as shown.
36. Remove the drive pinion by turning the forcing screw of the J 45234 Pinion Remover - 7.25 in Axle clockwise.
37. Remove the pinion oil seal using a suitable seal removal tool.
38. Remove the outer pinion bearing.
39. Remove the collapsible spacer from the pinion.
40. Remove the inner pinion bearing by installing the J 22912-B Pinion Bearing Remover between the pinion bearing and the pinion gear and pressing the bearing off the pinion.
41. Remove the pinion gear selectable shim.
42. Install the J 45228-4 to the outer pinion bearing cup as shown.
43. Install the J 45228-1 (2) and the J 45228-5 (1) to the J 45228-4. Seat the ridge of the J 45228-1 (2) into the outer pinion bearing cup bore.
44. Remove the outer pinion bearing cup by turning the J 45228-5 (1) clockwise.
45. Install the J 45228-4 to the inner pinion bearing cup as shown.
46. Install the J 45228-1 (1) and the J 45228-5 (2) to the J 45228-4.
47. Remove the outer pinion bearing cup by turning the J 45228-5 (2) clockwise.
48. Remove the upper differential carrier assembly bushing by performing the following steps: Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown. Remove the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.
49. Remove the lower differential carrier assembly bushing by performing the following steps: Install the J 45850-2 (2), the J 45850-3 (1), the forcing screw, the thrust bearing, and the nuts (3) over the differential carrier assembly bushing as shown. Remove the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850 Front Axle Bushing Remover/Installer.

Front Differential Case Disassemble

Special Tools

1. J 8107-2 Side Bearing Puller Pilot
2. J 22888-20A Universal Two Jaw Puller
3. J 22888-D Side Bearing Remover Kit

1. Place the differential case in a vise.
2. Install the J 22888-20A Universal Two Jaw Puller (2) and the J 8107-2 Side Bearing Puller Pilot (1) as shown.
3. Remove the differential side bearings using the J 22888-20A Universal Two Jaw Puller and the J 8107-2 Side Bearing Puller Pilot.
4. Remove the ring gear bolts.
5. Remove the ring gear from the differential case. Drive the ring gear off with a brass drift if necessary.
6. Remove the pinion shaft lock bolt.
7. Remove the pinion shaft.
8. Remove the differential pinion gears and the differential side gears. Roll the differential pinion gears out of the case with the pinion 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.

Differential Case Bearings Inspection

1. Inspect the bearings for smooth rotation after oiling.
2. Inspect the bearing rollers for wear.
3. Inspect the bearing cups for the following conditions: Wear Cracks Brinelling Scoring

Differential Case and Gears Inspection

1. Inspect the following components for excessive wear and/or fit: The pinion gear shaft The thrust washers The differential case for wear, cracks and scoring The fit of the pinion gear shaft in the differential case The fit of the differential side gears in the differential case The fit of the side gears on the axle shafts
2. Inspect the teeth of the pinion gears and the differential side gears for the following conditions: Wear Cracks Scoring Spalling
3. Replace any worn or poor fitting components as necessary.

Pinion and Ring Gear Inspection

1. The ring and pinion gears are matched sets and must be replaced any time a replacement of either is necessary.
2. Inspect the pinion and the ring gear teeth for the following conditions: Cracking Chipping Scoring Excessive wear
3. Inspect the pinion gear splines for wear.
4. Inspect the pinion flange splines for wear.
5. Inspect the fit of the pinion flange on the pinion gear.
6. Inspect the sealing surface of the pinion flange for nicks, burrs, or rough tool marks which will damage the inside diameter of the pinion seal and result in an oil leak.
7. Inspect all of the parts for wear and replace as necessary.

Thrust Washers, Shims, and Adjuster Sleeves Inspection

1. Inspect the shims and the thrust washers for cracks and chips. The damaged shims should be replaced with an equally sized service shim.
2. Inspect the adjuster sleeves for damaged threads. Replace if required.

Front Differential Case Assemble

Special Tools

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 8107-2 Side Bearing Puller Pilot
3. J 22888-D Side Bearing Remover Kit
4. J 33790 Differential Side Bearing Installer

1. Lubricate the pinion and side gears using axle lubricant. Use the proper fluid. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
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 side gears and the thrust washers to their original locations.
4. Install the differential pinion gears and 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 gear directly opposite of the first gear. Rotate the differential side gears until the pinion gears are directly opposite the opening in the differential case. Install the thrust washers. Rotate the pinion gears toward the differential case opening in order to permit the sliding in of the thrust washers.
5. Install the pinion gear shaft.
6. Install the new pinion gear shaft lock pin using a hammer and a brass drift.
7. Install the ring gear onto the differential case.
8. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.
9. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case and tighten to 84 N.m (67 lb ft).
10. Install the differential side bearings by performing the following steps: In order to protect the differential case, install the J 8107-2 Side Bearing Puller Pilot in the case on the side opposite the bearing installation. Install the J 33790 Differential Side Bearing Installer (2) and the J 8092 Universal Driver Handle - 3/4 in - 10 (1) onto the differential case bearing as shown. Install the differential case bearings using the J 33790 Differential Side Bearing Installer and the J 8092 Universal Driver Handle - 3/4 in - 10.

Front Differential Drive Pinion Gear Bearing Cup Installation

Tools Required

J 45228 Pinion Bearing Cup Remover and Installer

1. Install the inner pinion bearing cup into the inner pinion bearing cup bore.
2. Assemble the J 45228-1 (2), the J 45228-2 (3), and the J 45228-5 (1) into the pinion bearing cup bore as shown.
3. Tighten the J 45228-5 (1) slowly to draw the inner pinion cup into the inner pinion bearing cup bore. Inspect the position of the inner pinion bearing cup as it is being drawn into the pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45228 Pinion Bearing Cup Remover and Installer and the pinion bearing cup and reposition the inner pinion bearing cup.
4. Tighten the J 45228-5 (1) until the inner pinion bearing cup is seated in the inner pinion bearing cup bore.
5. Remove the J 45228 Pinion Bearing Cup Remover and Installer.
6. Install the outer pinion bearing cup into the outer pinion bearing cup bore.
7. Assemble the J 45228-1 (3), the J 45228-2 (2), and the J 45228-5 (1) into the pinion bearing cup bore as shown.
8. Tighten the J 45228-5 (1) slowly to draw the outer pinion cup into the outer pinion bearing cup bore. Inspect the position of the outer pinion bearing cup as it is being drawn into the pinion bearing cup bore to ensure the bearing cup is being pulled straight into the pinion bearing cup bore. If the pinion bearing cup is not being pulled straight into the bearing cup bore, remove the J 45228 Pinion Bearing Cup Remover and Installer and the pinion bearing cup and reposition the outer pinion bearing cup.
9. Tighten the J 45228-5 until the outer pinion bearing cup is seated in the outer pinion bearing cup bore.
10. Remove the J 45228 Pinion Bearing Cup Remover and Installer.

Pinion Depth Adjustment

Special Tools

1. J 29763 Static Timing Gauge
2. J 33838 Pinion Setting Gauge

For equivalent regional tools, refer to Special Tools .

1. Lubricate the pinion bearings with axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
2. Install the J 33838-2 (1) and the bolt (2) to the outer pinion bearing.
3. Install the J 33838-2 (1) and the bolt (2) with the outer pinion bearing into the differential carrier assembly case half.
4. Install the inner pinion bearing onto the J 33838 gauge as shown.
5. Install the J 33838 gauge (2) with the inner pinion bearing into the differential carrier assembly and the bolt (1).
6. While holding the J 33838 gauge stationary, install an inch-pound torque wrench on the bolt of the J 33838 gauge and tighten the bolt. Tighten Tighten the bolt until a rotating torque of 1.7-3.4 (15-30 lb in) for new bearings or 1.0-2.3 (10-20 lb in) for used bearings is obtained.
7. Rotate the assembly several times in both directions in order to seat the pinion bearings.
8. Check the rotating torque of the assembly. If the torque is less than 1.7 (15 lb in) for new bearings or 1.0 (10 lb in) for used bearings, continue to tighten the bolt until a rotating torque of 1.7-3.4 (15-30 lb in) for new bearings or 1.0-2.3 (10-20 lb in) for used bearings is obtained.
9. Place the contact pad of the J 33838 gauge into the differential side bearing bore.
10. Install the J 29763 gauge to the J 33838 gauge by doing the following: Install the collar and the lock nut onto the J 33838 gauge. Do not tighten the lock nut at this time. Install the J 29763 gauge into the collar. Place the stem of the J 29763 gauge onto the contact surface of the J 33838 gauge. With the stem of the J 29763 gauge touching the contact surface of the J 33838 gauge, push down on the J 29763 gauge until the needle of the J 29763 gauge has turned 3/4 of a turn clockwise. Tighten the lock nut of the J 29763 gauge finger tight.
11. Rotate the J 33838 gauge back and forth until the needle of the J 29763 gauge indicates the lowest point in the differential side bearing bore.
12. At the lowest point of deflection, move the housing of the J 29763 gauge (2) until the needle indicates ZERO.
13. Move the J 33838 gauge (1) back and forth again to verify the ZERO setting. Adjust the housing of the J 29763 gauge (2) as necessary to set the needle to ZERO.
14. After the ZERO setting is obtained and verified, grasp the J 33838 gauge (1) by the flats and move the contact pad of the J 33838 gauge out of the differential side bearing bore.
15. The value indicated on the J 29763 gauge (2) is the thickness of the shim needed in order to set the depth of the pinion.
16. Select the shim that indicates the proper thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
17. Remove the pinion depth setting tools.
18. Remove the pinion bearings from the pinion depth setting tools.
19. Assemble the differential carrier assembly. Refer to «Differential Carrier Assembly Assemble»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__differential-carrier-assembly-assemble) .

Differential Carrier Assembly Assemble

Special Tools

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 8614-01 Flange and Pulley Holding Tool
3. J 23423-A Case Bearing Race Installer
4. J 33782 Pinion Oil Seal Installer
5. J 33785 Pinion Bearing Installer
6. J 45224 Side Bearing Adjuster
7. J 45232 Differential Bearing Adjuster Needle Bearing Installer - LH

For equivalent regional tools, refer to Special Tools .

1. Install the selective shim between the inner pinion bearing and the shoulder of the pinion gear.
2. Install the inner pinion bearing (2) onto the pinion gear using the J 33785 installer (1).
3. Install the new collapsible spacer onto the pinion gear.
4. Lubricate the inner and the outer pinion bearings with the proper axle lubricant. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/express-g2500/2013-2013/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
5. Install the outer pinion bearing.
6. Install the oil seal by doing the following: Position the oil seal in the bore. Install the J 33782 installer over the oil seal. Strike the J 33782 installer with a hammer until the seal flange seats on the axle housing surface.
7. Install the pinion gear, the selectable shim with inner pinion bearing and the new collapsible spacer, into the left differential carrier case.
8. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke.
9. Install the pinion yoke.
10. Install the washer and a new pinion nut. If the new pinion nut cannot be installed, perform the following steps in order to seat the pinion yoke onto the pinion so that the washer and new pinion nut can be installed: Remove the pinion nut washer. Install the old pinion nut. Tighten the nut until a few of the shaft threads show through the nut so that the washer and new pinion nut can be installed. Remove the old pinon nut. Install the pinion nut washer Install the new pinion nut.
11. Install the J 8614-01 holding tool onto the pinion yoke as shown.
12. Tighten the pinion nut while holding the J 8614-01 holding tool. Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
13. Measure the rotating torque of the pinion using an inch-pound torque wrench. Specification The rotating torque of the pinion should be 1.7-3.4 (15-30 lb in) for new bearings or 1.0-2.3 (10-20 lb in) for used bearings.
14. If the rotating torque measurement is below 1.7 (15 lb in) for new bearings or 1.0 (10 lb in) for used bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 1.7-3.4 (15-30 lb in) for new bearings or 1.0-2.3 (10-20 lb in) for used bearings.
15. 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.
16. Install the left side differential carrier bearing, print side out, to the left side differential adjuster using the J 45232 installer - LH (2) and the J 8092 driver handle - 3/4 in - 10 (1).
17. Install the left inner shaft bearing and the differential bearing adjuster into the left differential carrier case using the J 45224 adjuster.
18. Install the left differential case bearing cup into the left differential carrier assembly case half using the J 23423-A installer and the J 8092 driver handle - 3/4 in - 10.
19. Install the right differential bearing adjuster into the differential case half using the J 45224 adjuster.
20. Install the right differential case side bearing cup into the right differential carrier case half using the J 23423-A installer (2) and the J 8092 driver handle - 3/4 in - 10 (1).
21. Install the differential case assembly into the left differential carrier case half.
22. Install the right differential carrier case half to the left differential carrier case half. Do not use sealer at this time. If the carrier case halves do not make complete contact, back out the right differential adjuster nut using the J 45224 adjuster.
23. Install the differential carrier case bolts and tighten to 48 (35 lb ft).
24. Turn the right side differential adjuster nut sleeve clockwise 1 1/2 revolutions using the J 45224 adjuster.
25. Using the J 45224 adjuster, turn the left differential adjuster nut sleeve clockwise in order to preload the differential side bearings against the differential side bearing cups and tighten to 75 (55 lb ft).
26. Rotate the pinion several times in order to seat the pinion and differential side bearings.
27. Measure the rotating torque of the drive pinion and differential assembly using an inch-pound torque wrench. Specification The rotating torque of the pinion and differential assembly should be 3.4-6.2 (30-55 lb in) for new bearings or 2.8-5.1 (25-45 lb in) for used bearings.
28. If the rotating torque measurement is below 2.8 (25 lb in) for used bearings, or 3.4 (30 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 45224 adjuster, turn the left and the right side differential adjuster nut sleeves in or clockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 29, if the rotating torque of the pinion and differential assembly is not within specifications, continue to tighten the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications
29. If the rotating torque measurement is above 5.1 (45 lb in) for used bearings, or 6.2 (55 lb in) for new bearings, adjust the differential side bearing preload using the following steps: Place an alignment mark between the differential adjuster nut sleeve and the differential carrier case, left and right sides. Using the J 45224 adjuster, turn the left and the right side differential adjuster nut sleeves out or counterclockwise one notch. Measure the rotating torque of the pinion and differential assembly using an inch-pound torque wrench. Compare the new measurement to the specification listed in step 29, if the rotating torque of the pinion and differential assembly is not within specifications, continue to loosen the left and right side differential adjuster nut sleeves one notch at a time on each side until the rotating torque of the pinion and differential assembly is within specifications
30. Once the specified rotating torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.
31. Measure the drive pinion to ring gear backlash. Refer to «Backlash Inspection and Adjustment»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__backlash-inspection-and-adjustment) .

Backlash Inspection and Adjustment

Special Tools

1. J 8001 Dial Indicator Set
2. J 45224 Side Bearing Adjuster

1. Mark the location of the differential adjuster nut sleeves in relation to the differential carrier halves. Ensure that the notches can be counted when turned.
2. Install the J 8001-1 (1, 2), the J 8001-2 (3), and the J 8001-3 (4) as shown. Ensure that the button contacts the outer edge of the pinion yoke and that the plunger is at a right angle to the pinion yoke.
3. Move the pinion yoke back and forth through the pinion flange's free play while not allowing the ring gear to move.
4. Record the dial indicator reading.
5. To determine the actual backlash, divide the dial indicator reading by 2. An actual dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash. 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 specification of 0.13-0.18 mm (0.005-0.007 in).
6. If the backlash is too small, increase the backlash by turning the left differential adjuster nut sleeve in one notch and the right differential adjuster nut sleeve out one notch using the J 45224 Side Bearing Adjuster.
7. If the backlash is too large, decrease the backlash by turning the right differential adjuster nut sleeve in one notch and the left differential adjuster nut sleeve out one notch using the J 45224 Side Bearing Adjuster.
8. Recheck the backlash and adjust as necessary.
9. Recheck the rotating torque of the pinion and differential assembly and adjust as necessary.
10. Once the backlash and rotating torque of the pinion and differential assembly is correct, perform a gear tooth contact pattern check to ensure proper contact between the pinion and the ring gear. Refer to «Gear Tooth Contact Pattern Inspection»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__gear-tooth-contact-pattern-inspection) .
11. Once the pinion and differential side bearing preload, the backlash, and the gear tooth contact pattern is within specifications, complete the assembly of the differential carrier assembly. Refer to «Differential Carrier Assembly Final Assembly»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__differential-carrier-assembly-final-assembly) .

Differential Carrier Assembly Final Assembly

Special Tools

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 42211 Axle Bearing Installer
3. J 42738 Seal Installer
4. J 45850 Front Axle Bushing Remover/Installer

1. Install the right side differential adjuster lock over the differential bearing adjuster.
2. Install the right side differential bearing adjuster lock bolt and tighten to 8 N.m (71 lb in).
3. Install the left side differential bearing adjuster lock over the differential adjuster.
4. Install the left side differential bearing adjuster lock bolt and tighten to 8 N.m (71 lb in).
5. Remove the differential carrier assembly bolts.
6. Remove the right differential carrier case half.
7. Clean the sealing surface of each half of the differential carrier case and the inner shaft housing to differential carrier assembly. The surfaces must be clean of all the grease and the oil.
8. Apply a bead of sealer GM P/N 1052942 (Canadian P/N 10953466) or the equivalent to one side of the differential carrier case half sealing surface.
9. Install the right differential carrier case half.
10. Install the differential carrier case bolts and tighten to 48 N.m (35 lb ft).
11. Install the lower inner shaft housing bushing by performing the following steps: Install the inner shaft housing into a vise. Place the lower inner shaft housing bushing over the bushing bore. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown. Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut. Install the lower inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore. Remove the inner shaft housing from the vise. Install the inner shaft housing into the vise. Clamp on the inner shaft housing tube.
12. Install the upper inner shaft housing bushing by performing the following steps: Install the inner shaft housing into a vise. Place the upper inner shaft housing bushing over the bushing bore. Install the J 45850-2 (2), J 45850-1 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the inner shaft housing bushing as shown. Install the J 45850-3 inside the J 45850-2 (2) in order to gain access to the upper nut. Install the upper inner shaft bushing by holding the lower nut and slowly tightening the upper nut in order to pull the bushing into the bushing bore.
13. Install the bearing with the square shoulder in using the J 42211 Axle Bearing Installer (2) and the J 8092 Universal Driver Handle - 3/4 in - 10 (1).
14. Install the new axle shaft seal using the J 42738 Seal Installer.
15. Remove the inner shaft housing from the vise.
16. Install the differential carrier assembly into a vise.
17. Apply sealant GM P/N 1052492 (Canadian P/N 10953466) or equivalent to the inner housing to differential carrier assembly sealing surface.
18. Install the inner shaft housing to the differential carrier assembly.
19. Install the inner shaft housing to differential carrier assembly bolts and tighten to 48 N.m (35 lb ft).
20. Install the new inner shaft retaining ring.
21. Install the inner shaft into the inner shaft housing by performing the following steps: Carefully guide the inner shaft through the inner shaft housing until the retaining ring on the inner shaft contacts the differential case side gear. Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
22. Install the inner shaft seal cover.
23. Install the inner shaft seal cover bolts and tighten to 18 N.m (13 lb ft).
24. Install the new inner shaft retaining ring.
25. Install the left inner shaft into the differential carrier assembly by performing the following steps: Carefully guide the inner shaft through the oil seal until the retaining ring on the inner shaft contacts the differential case side gear. Install the inner shaft into the differential case side gear by tapping the retaining ring into the retaining groove using a soft-faced mallet and until the retaining ring on the inner shaft is fully seated within the groove in the differential case side gear. Pull back on the inner shaft to ensure that the inner shaft is properly retained in the differential case side gear.
26. Install the lower differential carrier assembly bushing by performing the following steps: Install the differential carrier assembly bushing into the differential carrier assembly bushing bore. Install the J 45850-2 (3), the J 45850-3 (2), the forcing screw, the thrust bearing, and the nuts (1, 4-5) over the differential carrier assembly bushing as shown. Install the lower differential carrier assembly bushing by holding the upper nut and tightening the lower nut of the J 45850 Front Axle Bushing Remover/Installer.
27. Install the upper differential carrier assembly bushing by performing the following steps: Install the differential carrier assembly bushing into the differential carrier assembly bushing bore. Install the J 45850-2 (2), the J 45850-3 (3), the forcing screw, the thrust bearing, the washers, and the nuts (1) over the differential carrier assembly bushing as shown. Install the upper differential carrier assembly bushing by holding the lower nut and tightening the upper nut of the J 45850 Front Axle Bushing Remover/Installer.
28. Install the drain plug and the washer and tighten to 33 N.m (24 lb ft).
29. Fill the axle with lubricant with the proper fluid. Refer to «Front Axle Lubricant Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle) .
30. Install the fill plug and the washer and tighten to 33 N.m (24 lb ft).

Gear Tooth Contact Pattern Inspection

The 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. A pattern check ensures the best contact between the ring gear and the drive pinion for low noise and long life.

Scheme 78

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).

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.

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.

Backlash Adjustment

Adjust the backlash by means of moving the side bearing adjuster sleeves which move the case and ring gear assembly closer to or farther from the pinion. Also use the adjuster sleeves in order to set the side bearing preload.

1. If the left side adjuster sleeve is moved in, along with an equal outward movement of the right side adjuster, the backlash will increase.
2. If the left side adjuster sleeve is moved out, along with an equal inward movement of the right side adjuster, the backlash will decrease.

Testing Procedure

1. Wipe clean the differential case, the ring gear and the differential carrier 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. Using a wrench, turn the drive pinion flange/yoke so that the ring gear rotates at least 3 full revolutions.
4. Turn the drive pinion flange/yoke in the opposite direction so that the ring gear rotates at least 3 full revolutions in the opposite direction.
5. Observe the pattern on the ring gear teeth. Compare the pattern with the following illustrations.
6. Once the proper pattern is obtained, continue the assembly of differential carrier. Refer to «Differential Carrier Assembly Assemble»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#front-drive-axle__differential-carrier-assembly-assemble) .

Scheme 79

Condition

The backlash and pinion depth is correct.

Correction

None required.

Service Hints

Loose bearing 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. Drive pinion

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

Scheme 80

Condition

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

Correction

Adjust the pinion depth of drive pinion. Refer to Pinion Depth Adjustment .

Scheme 81

Condition

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

Correction

Adjust the pinion depth of drive pinion. Refer to Pinion Depth Adjustment .

Scheme 82

Condition

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

Correction

Decrease the backlash. Move the ring gear closer to the drive pinion by adjusting the side bearing adjuster sleeves. Refer to Backlash Inspection and Adjustment .

Scheme 83

Condition

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

Correction

Increase the backlash. Move the ring gear away from the drive pinion by adjusting the side bearing adjuster sleeves. Refer to Backlash Inspection and Adjustment .

The Front Drive Axle consist of the following components

1. The differential carrier housing
2. The differential assembly
3. The left and right output shafts
4. The inner axle shaft housing
5. The inner axle shaft

The front axle on the four-wheel-drive model vehicle does not have a central disconnect feature. The axle uses a conventional ring and pinion gear set in order to transmit the driving force of the engine to the wheels. The open differential allows the wheels to turn at different rates of speed while the axle continues to transmit the driving force. This prevents tire scuffing when going around corners and premature wear on internal axle parts. The ring and pinion set and the differential are contained within the carrier. The axle identification number on top of the differential carrier assembly or on a label on the right half of differential carrier assembly. The drive axles are completely flexible assemblies consisting of inner and outer constant velocity CV joints protected by thermoplastic boots and connected by a wheel drive shaft.

Illustration Tool Number/Description J 2619-01 Slide Hammer J 8001 Dial Indicator Set J 8092 Driver Handle J 8107-2 Side Bearing Puller Pilot J 8614-01 Flange and Pulley Holding Tool J 22888-D Side Bearing Remover Kit J 22888-A Universal Two Jaw Puller J 22912-01 Rear Pinion and Axle Bearing Remover J 23423-A Case Bearing Race Installer J 29369-1 Bushing and Bearing Remover J 29763 Static Timing Gauge J 33782 Pinion Oil Seal Installer J 33785 Pinion Bearing Installer J 33790 Differential Side Bearing Installer J 33838 Pinion Setting Gauge J 42211 Axle Bearing Installer J 42738 Seal Installer J 45224 Side Bearing Adjuster J 45228 Pinion Bearing Cup Remover/Installer J 45232 Differential Bearing Adjuster Needle Bearing Installer - LH J 45234 Pinion Remover - 7.25 Inch Axle J 45850 Front Axle Bushing Remover/Installer

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

See also:
• Vibration Diagnosis, Starting Point, and Correction
• Lifting and Jacking the Vehicle
• Fastener Caution
• Approximate Fluid Capacities
• Fluid and Lubricant Recommendations
• Wheel Drive Shaft Replacement
• Engine Protection Shield Replacement
• Tire and Wheel Removal and Installation (6-Lug Wheel)
• Front Brake Caliper Replacement (JH6, JH9)
• Front Brake Caliper Replacement (JH5)
• Pinion Flange/Yoke Installation Caution
• Front Propeller Shaft Replacement
• Trim Height Inspection
• Front Drive Axle Description and Operation
• Noisy in Drive
• Noisy When Coasting
• Intermittent Noise
• Constant Noise
• Noisy on Turns
• Front Axle Lubricant Leak Diagnosis
• Backlash Inspection and Adjustment
• Front Differential Case Disassemble
• Front Differential Case Assemble
• Front Differential Drive Pinion Gear Bearing Cup Installation
• Differential Carrier Assembly Assemble
• Front Axle Lubricant Level Inspection
• Adhesives, Fluids, Lubricants, and Sealers
• Gear Tooth Contact Pattern Inspection
• Differential Carrier Assembly Final Assembly
• Pinion Depth Adjustment