GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2003 🢒 Envoy - 4WD 🢒 Preface 🢒 Cautions and Notices 🢒 Rear Axle Shaft Replacement

Removal Procedure

    Object Number: 156409 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  3. Remove the brake caliper. Refer to Rear Brake Caliper Replacement .
  4. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  5. Remove the pinion shaft locking bolt.

    6. Object Number: 156410 Size: SH
  6. On axles without a locking differential, remove the pinion shaft.

    7. Object Number: 156411 Size: SH
  7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.

    8. Object Number: 156412 Size: SH
  8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the C-lock (1) until the C-lock aligns with the thrust block (2).
  9. Push the flange of the axle shaft (1) toward the differential.

    10. Object Number: 788486 Size: SH
  10. Remove the C-lock from the button end of the axle shaft.

    11. Object Number: 788488 Size: SH

    Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the installing of the axle shaft difficult.

  11. Remove the axle shaft from the housing.

Installation Procedure

    Object Number: 788488 Size: SH

    Important: Carefully insert the axle shaft in order to not damage the seal.

  1. Install the axle shaft into the rear axle housing.
  2. Slide the axle shaft into place allowing the splines to engage the differential side gear.

    3. Object Number: 788486 Size: SH
  3. On axles without a locking differential, place the C-lock on the button end of the axle shaft.
  4. On axles with a locking differential, keep the pinion shaft partially withdrawn.

    5. Object Number: 156412 Size: SH
  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. Pull the shaft flange outward in order to seat the C-lock in the differential gear.

    7. Object Number: 156409 Size: SH
  7. Align the hole in the pinion shaft with the bolt hole in the differential case.

    8. 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.

  8. Install the new pinion shaft locking bolt.

    9. Tighten
    Tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).

  9. Install the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  10. Install the brake caliper. Refer to Rear Brake Caliper Replacement .
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  12. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Level Inspection .
  13. Lower the vehicle.