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Home >> Chevrolet >> 2020 >> Express 2500 LS, 6.0L Eng VIN G >> Repair and Diagnosis >> External Pages >> Different car >> Section 45 (Rear Drive Axle) >> Repair Instructions >> Differential Overhaul (9.5 Inch Axles) >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2019 GMC Savana 3500, 2019 GMC Savana 2500, 2019 Chevrolet Express 3500, and 2019 Chevrolet Express 2500. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the pinion and side gears using the proper axle lubricant. Fluid and Lubricant Recommendations
  2. Install the differential side gear thrust washers (4) to the differential side gears (5).
  3. GM2152359
    NOTE:

    If the same differential side gears and the thrust washers are being used, install the gears and the thrust washers to their original locations.

    Install the differential side gears (5) and thrust washers (4) into the differential case (2).

  4. Position one pinion gear (7) between the differential side gears (5).
  5. Position the second pinion gear (7) between the differential side gears (5).
  6. Rotate the differential side gears (5) until the pinion gears (7) are directly opposite the opening in the differential case (2).
  7. Rotate the pinion gears (7) toward the differential opening.
  8. Install the thrust washers (6) on the pinion gears (5).
  9. Rotate the pinion gears until they are aligned with the holes in the differential case (2) for the pinion shaft (1).
  10. Install the pinion shaft (1).
    11. CAUTION:

    Refer to Fastener Caution .

  11. Install the NEW differential pinion gear shaft locking bolt and tighten to.
    • For the 8.6 inch axle, tighten the pinion bolt to 36 N.m (27 lb ft).
    • For the 9.5 inch axle, tighten the pinion bolt to 50 N.m (37 lb ft).
  12. Install the differential ring gear to the differential case. Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) , or Drive Pinion and Ring Gear Replacement (9.5 Inch Axle) 
  13. Install the differential side bearings. Differential Bearing Replacement 
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