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 MANUALSCHEVROLET1998EXPRESS 1 TON VAN V8-5.7L VIN RREPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINDIFFERENTIAL ASSEMBLYSERVICE AND REPAIRUNIT REPAIRDIFFERENTIAL CASE ASSEMBLY
1998 Chevrolet Express 1 Ton Van V8-5.7L VIN R
Differential Case Assembly
1998 Chevrolet Express 1 Ton Van V8-5.7L VIN RSECTION Differential Case Assembly
^ Tools Required
- J24385-01 Differential Case Spreader
- J39705 Master Differential Bearings
1. Lubricate all parts with an axle lubricant.
2. Install new thrust washers to the side gears.
3. Install the side gears to the differential case.
IMPORTANT: Install the side gears to the same side that the side gears were on when removed.
4. Install the pinion gears to the differential without the thrust washers.
4.1. Install the pinion gears to the side gears so that the holes in the pinion gears are 180 degrees apart.
4.2. Rotate the pinion gears into place. Verify that the pinion gears line up with the pinion shaft holes.
5. Rotate the pinion gears toward the differential opening in order to allow enough space for the pinion thrust washers to slide in.
6. Install the pinion shaft.
7. Align the roll pin holes in the differential case and the pinion shaft.
8. Install the roll pin.
8.1. Peen metal from the case over the lock pin in two places that are 180 degrees apart.
8.2. Make sure the mating surfaces of the differential case and the ring gear are clean and free of burrs.
9. Align the holes in the differential case and the holes in the ring gear. Press the ring gear onto the case.
NOTICE: Refer to Fastener Notice in Service Precautions.
10. Install new ring gear bolts.
^ Tighten the ring gear bolts in sequence to 298 Nm (220 ft. lbs.).
IMPORTANT: Tighten the ring gear bolt in stages in order to gradually pull the ring gear onto the differential case.
11. Install the J39705 to the differential.
^ Refer to Determining Total Shim Pack Size.
^ Put the outboard spacers in place, if outboard spacers are used.
- J24385-01 Differential Case Spreader
- J39705 Master Differential Bearings
1. Lubricate all parts with an axle lubricant.
2. Install new thrust washers to the side gears.
3. Install the side gears to the differential case.
IMPORTANT: Install the side gears to the same side that the side gears were on when removed.
4. Install the pinion gears to the differential without the thrust washers.
4.1. Install the pinion gears to the side gears so that the holes in the pinion gears are 180 degrees apart.
4.2. Rotate the pinion gears into place. Verify that the pinion gears line up with the pinion shaft holes.
5. Rotate the pinion gears toward the differential opening in order to allow enough space for the pinion thrust washers to slide in.
6. Install the pinion shaft.
7. Align the roll pin holes in the differential case and the pinion shaft.
8. Install the roll pin.
8.1. Peen metal from the case over the lock pin in two places that are 180 degrees apart.
8.2. Make sure the mating surfaces of the differential case and the ring gear are clean and free of burrs.
9. Align the holes in the differential case and the holes in the ring gear. Press the ring gear onto the case.
NOTICE: Refer to Fastener Notice in Service Precautions.
10. Install new ring gear bolts.
^ Tighten the ring gear bolts in sequence to 298 Nm (220 ft. lbs.).
IMPORTANT: Tighten the ring gear bolt in stages in order to gradually pull the ring gear onto the differential case.
11. Install the J39705 to the differential.
^ Refer to Determining Total Shim Pack Size.
^ Put the outboard spacers in place, if outboard spacers are used.
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.