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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) >> Removal Procedure

Removal 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.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the brake caliper. Refer to Brake Caliper Replacement - Rear (1500 Series) or Brake Caliper Replacement - Rear (2500/3500 Series) in Disc Brakes.
  4. Remove the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  5. Remove the pinion shaft locking bolt.
    6. Fig 1: View Of Pinion Shaft Locking Bolt
    GM156409Courtesy of GENERAL MOTORS CORP.
  6. On axles without a locking differential, remove the pinion shaft.
    7. Fig 2: View Of Pinion Shaft
    GM156410Courtesy of GENERAL MOTORS CORP.
  7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.
    8. Fig 3: Pinion Shaft Touching Housing
    GM156411Courtesy of GENERAL MOTORS CORP.
  8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2).
    9. Fig 4: View Of Axle Shaft, Lock & Thrust Block
    GM156412Courtesy of GENERAL MOTORS CORP.
  9. Push the flange of the axle shaft (1) toward the differential.
  10. Remove the C-lock (4) from the button end of the axle shaft (1).
    11. IMPORTANT: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult.
  11. Remove the axle shaft (1) from the housing (5).
    12. Fig 5: Axle Shaft Housing & Components
    GM391222Courtesy of GENERAL MOTORS CORP.
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