GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Astro - 4WD 🢒 Engine 🢒 Engine Electrical 🢒 Differential Carrier Assembly Replacement

Removal Procedure
  1. Unlock the steering column so that the steering linkage is free to move.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    3. Object Number: 598199 Size: SH
  3. Remove the drain plug and the flat washer. Drain the fluid from the axle.

    4. Object Number: 179841 Size: SH
  4. Remove the vent hose from the differential carrier.

    5. Object Number: 161384 Size: SH
  5. Remove the idler arm bolts.
  6. Reposition the steering linkage to allow for the removal of the carrier.
  7. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  8. Remove the left and the right wheel drive shafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    9. Object Number: 161386 Size: SH
  9. Support the differential carrier assembly.
  10. Remove the inner axle shaft housing and the inner axle shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement .
  11. Remove the differential carrier assembly upper mounting bolt and the nut.

    12. Object Number: 161390 Size: SH
  12. Remove the differential carrier assembly lower mounting nuts and the bolts.
  13. Remove the differential carrier assembly from the vehicle. Roll the carrier as necessary to clear the mounting brackets, the oil pan, and the steering linkage.

Installation Procedure
  1. Install the differential carrier assembly to the vehicle.

    2. Object Number: 161390 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the differential carrier assembly mounting bolts and the nuts.

    3. Tighten
    Tighten the differential carrier assembly mounting bolts to 85 N·m (63 lb ft).

  3. Install the inner axle shaft housing and the inner axle shaft. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement .
  4. Install the left and the right wheel drive shafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  5. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
  6. Reposition the steering linkage.
  7. Install the idler arms to the frame.

    8. Tighten
    Tighten the idler arm bolts to 105 N·m (77 lb ft).


    Object Number: 179841 Size: SH
  8. Install the axle vent hose.

    9. Object Number: 598199 Size: SH
  9. Install the drain plug and the flat washer.

    10. Tighten
    Tighten the drain plug to 30 N·m (22 lb ft).

  10. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  11. Inspect the axle lubricant level and add, if necessary. Refer to Front Axle Lubricant Level Inspection .
  12. Lower the vehicle.