Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1998ASTRO VAN 2WD V6-4.3L VIN WREPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINDIFFERENTIAL ASSEMBLYSERVICE AND REPAIRUNIT REPAIRDIFFERENTIAL CASE ASSEMBLY
1998 Chevrolet Astro Van 2WD V6-4.3L VIN W
Differential Case Assembly
1998 Chevrolet Astro Van 2WD V6-4.3L VIN WSECTION Differential Case Assembly
INSTALLATION PROCEDURE
^ Tools Required
- J8092 Driver Handle
- J8107-4 Differential Side Bearing Puller Pilot
- J25299 Differential Side Bearing Installer
1. Lubricate all the parts with axle lubricant.
2. Install the thrust washers to the side gears.
3. Install the side gears to the differential case on the same side in which the parts were removed.
4. Place one pinion gear on the side gear. Rotate the gear until the pinion is exactly opposite the differential opening.
Install the pinion gears to the differential without the thrust washers.
5. Rotate the pinion gears into place. Verify the gears line up with the pinion shaft holes.
6. Install the pinion shaft.
7. Install the pinion shaft lock bolt finger tight.
8. Inspect the mating surfaces of the differential case for cleanliness, and that the surfaces are free of burrs.
9. Install the ring gear to the differential case.
10. Install two threaded studs into the ring gear on opposite sides.
11. Place the ring gear on the case. Align the studs with the holes in the case.
12. Install the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ Tighten the ring gear bolts in sequence to 120 Nm (90 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
13. Install the differential side bearings, using J25299, J8092, and J8107-4.
^ In order to protect the differential case, place J8107-4 in the case on the side opposite the bearing installation.
^ Drive the bearing onto the case using J25299 and J8092.
14. Install the differential case to the axle housing. Refer to Differential Side Bearing Preload Adjustment.
^ Tools Required
- J8092 Driver Handle
- J8107-4 Differential Side Bearing Puller Pilot
- J25299 Differential Side Bearing Installer
1. Lubricate all the parts with axle lubricant.
2. Install the thrust washers to the side gears.
3. Install the side gears to the differential case on the same side in which the parts were removed.
4. Place one pinion gear on the side gear. Rotate the gear until the pinion is exactly opposite the differential opening.
Install the pinion gears to the differential without the thrust washers.
5. Rotate the pinion gears into place. Verify the gears line up with the pinion shaft holes.
6. Install the pinion shaft.
7. Install the pinion shaft lock bolt finger tight.
8. Inspect the mating surfaces of the differential case for cleanliness, and that the surfaces are free of burrs.
9. Install the ring gear to the differential case.
10. Install two threaded studs into the ring gear on opposite sides.
11. Place the ring gear on the case. Align the studs with the holes in the case.
12. Install the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
^ Tighten the ring gear bolts in sequence to 120 Nm (90 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
13. Install the differential side bearings, using J25299, J8092, and J8107-4.
^ In order to protect the differential case, place J8107-4 in the case on the side opposite the bearing installation.
^ Drive the bearing onto the case using J25299 and J8092.
14. Install the differential case to the axle housing. Refer to Differential Side Bearing Preload Adjustment.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.