GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Express - AWD 🢒 General Information 🢒 General Information 🢒 Differential Carrier Assembly Replacement

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Place a jack or utility stands, such as GMTG 123-B67313, at the rear end of the vehicle.
  3. Drain the fluid from the differential carrier assembly . Refer to Front Axle Lubricant Replacement .

    4. Object Number: 1199415 Size: SH
  4. Disconnect the propeller shaft from the differential carrier assembly. Refer to Front Propeller Shaft Replacement .

    5. Support the propeller shaft as necessary.

  5. Remove the engine protection shield. Refer to Engine Protection Shield Replacement .
  6. Remove the front engine crossmember. Refer to Engine Front Crossmember Replacement .

    7. Object Number: 1199384 Size: SH
  7. Place a transmission jack under the differential carrier assembly.

    8. 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. Object Number: 1199394 Size: SH
  9. Remove the wheel drive shaft to inner shaft bolts.

    10. Object Number: 1199424 Size: SH
  10. Disconnect the left side wheel drive shaft from the inner shaft.

    11. Object Number: 1199417 Size: SH
  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. Object Number: 1199431 Size: SH
  13. Remove the upper inner shaft housing mounting bolt.
  14. Remove the upper differential carrier assembly mounting bolt.

    15. Object Number: 1199382 Size: SH
  15. Remove the differential carrier assembly.

Installation Procedure

    Object Number: 1199382 Size: SH
  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.

    4. Do not tighten the bolt to specification at this time.


    Object Number: 1199431 Size: SH
  4. Install the inner shaft upper mounting bolt and the nut.

    5. Do not tighten the bolt to specification at this time.

  5. Install the front engine crossmember. Refer to Engine Front Crossmember Replacement .

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Tighten the upper differential carrier assembly and inner shaft housing mounting bolts.

    7. Tighten
    Tighten the upper differential carrier assembly and inner shaft housing mounting bolts to 85 N·m (63 lb ft).


    Object Number: 1199424 Size: SH
  7. Connect the left side wheel drive shaft to the inner shaft flange.

    8. Align the marks made during removal.

  8. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    9. 8.1. Remove all traces of the original adhesive patch.
    8.2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    8.3. 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.

    10. Tighten
    Tighten the wheel drive shaft to inner shaft flange bolts to 50 N·m (37 lb ft)


    Object Number: 1199417 Size: SH
  10. Connect the right side wheel drive shaft to the inner shaft flange.

    11. Align the marks made during removal.

  11. Perform the following procedure before installing the wheel drive shaft to inner shaft bolts:
    12. 11.1. Remove all traces of the original adhesive patch.
    11.2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    11.3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) to the threads of the bolts.

    Object Number: 1199394 Size: SH
  12. Install the right side wheel drive shaft to inner shaft bolts.

    13. Tighten
    Tighten the wheel drive shaft to inner shaft flange bolts to 50 N·m (37 lb ft)

  13. Install the engine protection shield. Refer to Engine Protection Shield Replacement .
  14. Connect the propeller shaft to the differential carrier assembly. Refer to Front Propeller Shaft Replacement .
  15. Fill the differential carrier assembly with the proper lubricant. Refer to Front Axle Lubricant Replacement .
  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 .