GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Express 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Drive Pinion and Ring Gear Replacement

Drive Pinion and Ring Gear Replacement 8.6 Inch Axle

Tools Required

J 22536 Pinion Driver

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the differential assembly. Refer to Differential Replacement .
  3. Remove the pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .

    4. Object Number: 683960 Size: SH
  4. Install the J 22536 as shown.

    5. Ensure that the J 22536 is firmly seated on the pinion.

  5. Drive the pinion out using the J 22536 and a hammer.

    6. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.


    Object Number: 9731 Size: SH
  6. Remove the collapsible spacer from the pinion. Discard the spacer.
  7. Remove the pinion bearings and the cups. Refer to Drive Pinion Bearings Replacement .

    8. Object Number: 866503 Size: SH

    Important: The ring gear bolts have left-hand threads.

  8. Remove the ring gear bolts. Discard the bolts.

    9. Notice: Refer to Ring Gear Removal Notice in the Preface section.


    Object Number: 866502 Size: SH
  9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.

Installation Procedure

    Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.


    Object Number: 866505 Size: SH
  1. Install the ring gear to the differential case.

    2. Object Number: 866503 Size: SH

    Important: The ring gear bolts have left-hand threads.

  2. Install the new ring gear bolts.

    3. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

    Notice: Refer to Fastener Notice in the Preface section.

  3. Tighten the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

    4. Tighten
    Tighten the ring gear bolts in sequence to 120 N·m (89 lb ft).

  4. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement .
  5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment .
  6. Install the selective shim onto the pinion.
  7. Install the inner pinion bearing to the pinion. Refer to Drive Pinion Bearings Replacement .
  8. Install a new collapsible spacer.
  9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations .
  10. Install the outer pinion bearing into the axle housing.
  11. Install the new pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  12. Install the pinion into the axle housing.
  13. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  14. Install the differential assembly. Refer to Differential Replacement .
  15. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement .
  16. Lower the vehicle.

Drive Pinion and Ring Gear Replacement 9.75, 10.5 and 10.75 Inch Axles

Special Tools

J 22536 Pinion Driver

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
  2. Remove the differential assembly. Refer to Differential Replacement.
  3. Remove the drive pinion yoke and the pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement.

    4. Object Number: 815631 Size: SH
  4. Remove the thrust washer.

    5. Object Number: 683960 Size: SH
  5. Install the J 22536 as shown.

    6. Ensure that the J 22536 is firmly seated on the pinion.

  6. Drive the pinion out using the J 22536 and a hammer.

    7. Strike the J 22536 slowly. Do not let the pinion fall out of the rear axle housing.

  7. Remove the pinion preload shims from the drive pinion and set aside.
  8. Remove the inner pinion bearing and the pinion position shim. Refer to Drive Pinion Bearings Replacement.

    9. Object Number: 866503 Size: SH

    Important: The ring gear bolts have right-hand threads.

  9. Remove the ring gear bolts. Discard the bolts.

    10. Notice: Refer to Ring Gear Removal Notice in the Preface section.


    Object Number: 866502 Size: SH
  10. Remove the ring gear from the differential case. Drive the gear off with a brass drift if necessary.

Installation Procedure
  1. Determine the pinion position shim thickness and the pinion preload shim thickness for the drive pinion gear. Refer to Pinion Depth Adjustment.

    2. Object Number: 866505 Size: SH

    Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear.

  2. Install the ring gear to the differential case.

    3. Align the holes in the differential case to the bolts holes in the ring gear.

    Important: The ring gear bolts have right-hand threads.


    Object Number: 866503 Size: SH
  3. Install the new ring gear bolts.

    4. Hand start each bolt to ensure that the ring gear is properly installed to the differential case.

    Notice: Refer to Fastener Notice in the Preface section.

  4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.

    5. Tighten
    Tighten the new ring gear bolts to 177 N·m (131 lb ft).

  5. Install the differential assembly. Refer to Differential Replacement.
  6. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement.
  7. Lower the vehicle.