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How to Replace Differential Cover 02-05 Chevy Suburban

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  1. step : Removing the Differential Cover (0:41)
    • Remove severe rust from the differential cover bolts with a hammer and chisel
    • Remove all but the bottom 13mm bolts from the differential cover
    • If removing rust made the bolts smaller, hammer a 1/4 inch socket onto the bolts
    • Have a drain pan ready
    • Remove the bottom 13mm bolts from the differential cover
    • Pry out the bottom of the differential cover with the hammer and chisel
    • Thread the top 13mm bolt into the differential cover
    • Allow the fluid to drain
    • Pry out the bottom of the differential cover with the chisel
    • Remove the top 13mm bolt
    • Pull the differential cover down and out
  2. step : Cleaning the Differential (3:33)
    • Clean any debris out of the differential with a vacuum
    • Clean the differential with a cloth rag
    • Scrape off the old differential cover gasket with a razor blade
    • Clean any residue with a wire brush
  3. step : Preparing the New Differential Cover (4:14)
    • Apply RTV to the new differential cover
    • Place the gasket onto the differential cover, lining up the bolt holes
    • Apply RTV to the gasket
  4. step : Installing the New Differential Cover (4:57)
    • Clean any fluid off of the mounting surface with a cloth rag
    • Put the differential cover into place
    • Thread the top 13mm bolt into the differential cover
    • Thread the remaining 13mm bolts
    • Replace the wiring harness connected to one of the top bolts
    • Let the RTV set
    • Tighten the 13mm bolts to 15 foot-pounds of torque in a crossing pattern
  5. step : Refilling the Differential (6:13)
    • Remove the filler plug with a 3/8 inch ratchet
    • If necessary, hammer the ratchet into the plug
    • Add fluid to the differential until it drips out the fill hole
    • Check that the fluid level is up to the fill hole
    • Tighten the fill plug into the fill hole

Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.

Hi, I'm Mike from 1A Auto. I hope this how-to video helps you out, and, please, next time you need parts for your vehicle, think of 1AAuto.com.

In this video, we're going to show you how to replace the rear differential cover on this 2002 Chevy Suburban. The items that you'll need for this are a new rear differential cover from 1AAuto.com, 13 mm socket and ratchet with an extension, 3/8 inch ratchet, hammer and cold chisel, vacuum, razor blade, rags, wire brush, drip pan, differential fluid, and jack and jack stands.

The rear differential cover is right up under back here. We do have the spare tire removed on this suburban. That makes it a little easier. The bolts on our vehicle are pretty rust, and that's usually what happens. These differential covers actually rust out. What we're doing is using a cold chisel and just knocking the scale off of each side of the bolt. Now, the bolts are actually 13mm, but what we've found is since we took that scale off, it's slightly smaller, so we're driving a 1/2 inch socket on there. That gives it a good enough grip to get them all out. We'll just repeat that process for all ten of the bolts. Make sure you have a drip pan below the differential cover before you remove the last of the bottom bolts. You want to just remove those. Using your chisel, just hammer out on the bottom of the differential cover. Then replace the bolt at the top of the differential cover. Then use your chisel and hammer again on the other side. Just let the fluid drain out. After it's drained for a while, just pry out on the bottom and remove that bolt. Then pull the cover down and out.

If any debris falls down inside of here, as you can see right there, you just want to vacuum all of it out. Then take a rag, make sure it's somewhat clean and just wipe everything down. Just stick this rag back in there. Then using a razor blade, just cut off that old gasket along the outside. Then, just use a wire brush to get any leftover residue of the gasket.

The new differential cover from 1Aauto does come with a gasket, but we use a small bead of RTV on each side of the gasket just to make sure it has a good seal. Just make sure it's pressed down into place and then trace it with more RTV.

Make sure there's no fluid on the outside here. Then take your differential cover and feed it up into place. You want to just replace the top bolt to hold it in. Then, we'll just fast forward as he replaces the rest of the bolts. Make sure for this top bolt that you put this harness back into place. Then let the gasket sit for a minute, if you used RTV. Then, tighten each of those bolts up. Then you want to just torque each of these to 15 foot pounds in a crossing pattern.

Now remove this filler plug using your 3/8 ratchet. Ours is in kind of rough condition, so I'm just going to hammer the ratchet into place. Then just remove that plug. Now replace the differential fluid. You want to do this until it starts to pour over the side. When it starts to pour over the side, you just put your pink in there, make sure the fluid's right to the top of the filler hole. If it is, then you're all set. You can replace your cap. Just tighten that up with your ratchet, and you're all set.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Chisel
  • Floor Jack
  • Jack Stands
  • Razor Blade / Gasket Scraper
  • Wire Brush
  • Hammer
  • Drain Pan

  • Materials, Fluids, and Supplies

  • Cloth Rags
  • RTV
  • Gear Oil

  • Ratchets & Related

  • Socket Extensions
  • 3/8 Inch Drive Ratchet
  • Torque Wrench

  • Sockets - Metric

  • 13mm Socket

  • Sockets - SAE

  • 1/2 Inch Socket

  • Specialty Tools

  • Vacuum

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Rear Differential Cover

Rear Differential Cover DIY Solutions ADS00112

This part replaces:

  • Dorman 697-700
  • OE # 26067595

Part Details

  • Includes: Gasket
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