LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1014 (Rear Drive Axle) >> Repair Instructions >> Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: Carefully insert the axle shaft in order to not damage the seal.
  1. Install the axle shaft (1) into the rear axle housing (5).
  2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear.
  3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1).
    4. Fig 1: Axle Shaft Housing & Components
    GM391222Courtesy of GENERAL MOTORS CORP.
  4. On axles with a locking differential, keep the pinion shaft partially withdrawn.
  5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2).
    6. Fig 2: View Of Axle Shaft, Lock & Thrust Block
    GM156412Courtesy of GENERAL MOTORS CORP.
  6. Pull the shaft flange outward in order to seat the lock in the differential gear.
  7. Align the hole in the pinion shaft with the bolt hole in the differential case.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the new pinion shaft locking bolt.

    Tighten: 

    • For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N.m (27 lb ft).
    • For the 9.5 inch axle, tighten the pinion shaft locking bolt to 50 N.m (37 lb ft).

    9. Fig 3: View Of Pinion Shaft Locking Bolt
    GM156409Courtesy of GENERAL MOTORS CORP.
  9. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  10. Install the brake caliper. Refer to Brake Caliper Replacement - Rear (1500 Series) or Brake Caliper Replacement - Rear (2500/3500 Series) in Disc Brakes.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Fill the rear axle. Use the proper fluid. Refer to Capacities - Approximate Fluid and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  13. Lower the vehicle.
scientia non olet · About LEMON Manuals