2002 Chevrolet Silverado Change Rear Differential Fluid

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In 1999, Chevrolet replaced the C and K-series of pickups with the Silverado. The 2002 Silverado came in three different sizes 1500, 2500 and 3500HD. The engine sizes ranged from a 4.3-liter V-6 that produced 200 horsepower in the 1500 to an 8.1-liter V-8 that produced 340 horsepower in the 3500HD. All three sizes of the 2002 Silverado had five rear axles to choose from, 8-3/5 inch, 9-1/2 inch, 9-3/4 inch, 10-1/2 inch and 11-1/2 inch. All of the axles undergo the same process to replace the differential fluid, only the fluid capacities change.

[edit] Tools Used

Tools
Wheel chocks
Floor jack
Jack stands
Ratchet
Drain pan
Clean shop rag
3 to 4 quarts 75W-90 synthetic gear oil
Torque wrench

[edit] Change Rear Differential Fluid

  • Place the wheel chocks around the front wheels of the Silverado to prevent them from rolling while jacking up the truck.
  • Raise the rear of the truck using a floor jack and slide the jack stands beneath the axle. Lower the jack until the Silverado's weight is supported only by the jack stands. Remove the floor jack.
  • Slide the drain pan under the drain plug on the rear differential "pumpkin" -- the large orb in the center of the rear axle.
  • Remove the check and fill plug at the top of the "pumpkin" with a ratchet. Remove the drain plug at the bottom of the "pumpkin" with a ratchet. Allow all of the gear oil to drain from the rear differential.
  • Clean the drain plug, and then the check and fill plug with a clean shop cloth.
  • Reinstall the drain plug and tighten it to 20 foot-pounds on the 9-3/4-inch rear differential and 24 foot-pounds on all other size differentials, using a torque wrench.
  • Fill the differential with 75W-90 synthetic gear oil through the check and fill hole. The 8-3/5-inch differential requires 2.41 quarts., the 9-1/2- and 10-1/2-inch differentials require 2.75 quarts., the 9-3/4-inch differential uses 3 quarts. and the 11-1/2 inch uses 3.83 quarts.
  • Insert the check and fill plug and tighten it to 15 foot-pounds on the 9-3/4-inch differential and 24 foot-pounds on all other sizes, using a torque wrench.
  • Raise the Silverado up from the jack stands with a floor jack and slide the stands from under the truck. Lower the Chevrolet to the ground. Remove the wheel chocks from the front wheels.

[edit] Tips & Warnings

  • Always remove the fill (upper) plug first. This way, if you have trouble loosening it, you're not left with an empty differential.
  • After the maintenance is complete, take the old differential fluid to a fluid recycling center. Many auto parts stores perform this task free of charge.
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