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Home >> Chevy Truck >> 2000 >> C 6500 Kodiak V8-7.4L VIN D >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Removal and Replacement >> Rear Drive Axle >> Rear Axle Housing Replacement

Rear Axle Housing Replacement




Rear Axle Housing Replacement

Removal Procedure





Important: Shift the two speed rear axle into LOW range, if equipped.


1. Block the front wheels.
2. Raise and support the vehicle under the frame rails. Ensure that the vehicle rear wheels are off the floor. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
3. Support the rear axle housing.

* Use a hydraulic transmission dolly with adapters in order to properly handle the rear axle housing.
* Fasten a chain over the top of the rear axle housing and to both sides of the hydraulic transmission dolly.

4. Release the parking brake.
5. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Disc Type-Single Front/Rear) Tire and Wheel Removal and Installation (Disc Type-Single Front/Rear)Tire and Wheel Removal and Installation (Disc Type-Dual) Tire and Wheel Removal and Installation (Disc Type-Dual)Tire and Wheel Removal and Installation (Cast Type-Single Front/Rear) Tire and Wheel Removal and Installation (Cast Type-Single Front/Rear)Tire and Wheel Removal and Installation (Cast Type-Dual) Tire and Wheel Removal and Installation (Cast Type-Dual) in Tires and Wheels.
6. Remove the Axle Shaft, Drum, Hub, Hub/Rotor. Refer to following procedures:

* Rear Hub and Bearing Replacement Rear Hub and Bearing Replacement
* Brake Drum Replacement
* Rear Axle Shaft and/or Gasket Replacement Service and Repair

7. Remove the rear axle lubricant. Refer to Lubricant Change Service and Repair.
8. Remove the propeller shaft. Refer to the following procedures in Propeller Shaft:

* Propeller Shaft Replacement - One Piece - Flange Type Propeller Shaft Replacement - One Piece - Flange Type
* Propeller Shaft Replacement - One-Piece - Yoke Type Propeller Shaft Replacement - One-Piece - Yoke Type
* Propeller Shaft Replacement - Two Piece - Flange Type Propeller Shaft Replacement - Two Piece - Flange Type
* Propeller Shaft Replacement - Two Piece - Yoke Type Propeller Shaft Replacement - Two Piece - Yoke Type
* Propeller Shaft Replacement - Three Piece - Flange Type Propeller Shaft Replacement - Three Piece - Flange Type
* Propeller Shaft Replacement - Three Piece - Yoke Type Propeller Shaft Replacement - Three Piece - Yoke Type
* Tandem Axle Propeller Shaft Replacement Tandem Axle Propeller Shaft Replacement

9. Remove the rear air brake assemblies, if equipped. Refer to Rear Cam Brake Assembly Replacement in Air Drum.
10. Remove the rear brake caliper mounting plate, if equipped. Refer to Brake Caliper Mounting Plate Replacement (Front, Bendix) Brake Caliper Mounting Plate Replacement (Front, Dayton-Walther) Brake Caliper Mounting Plate Replacement (Rear, Bendix Rail Slider) Brake Caliper Mounting Plate Replacement (Rear, Dayton-Walther Rail) in Disc Brakes.
11. Remove the two speed rear axle shift motor, if equipped. Refer to Two Speed Rear Axle Shift Motor Replacement (HPZ) Two Speed Rear Axle Shift Motor Replacement (HPZ)Two Speed Rear Axle Shift Motor Replacement (HR2) Two Speed Rear Axle Shift Motor Replacement (HR2).
12. Remove the differential lock air line, if equipped.
13. Remove the wiring attached to the rear axle housing.




14. Remove the rear axle tie rod, if equipped.




15. Remove the rear suspension control arms, if equipped. Refer to Torque Rod Replacement Rear Suspension in Rear Suspension.
16. Remove the rear shock absorber from the rear shock absorber lower bracket.
17. Remove the following components from the rear axle stabilizer shaft. Disconnect the components only from the rear axle housing:

* The nuts
* The washers
* The bolts, if equipped




18. Remove the following rear spring components:

* The U-bolts
* The nuts
* The washers

19. Remove the rear shock absorber lower bracket, if equipped.
20. Remove the rear spring anchor plate bracket.
21. Remove the rear axle housing from the suspension.
22. Remove the differential carrier. Complete the following steps:

1. Set the rear axle housing on an axle stand with the differential carrier facing up.
2. Remove the following differential carrier components:

* The bolts
* The nuts, if equipped
* The washers

3. Strike the differential carrier housing with a rubber mallet in order to break the seal.
4. Lift the differential carrier from the rear axle housing. Use a chain lift or equivalent.

23. Clean the differential carrier seal surface.
24. Clean the rear brake drum or the rear bake rotor, and the rear brake assemblies using Brake Parts Cleaner GM P/N 12345754 or equivalent.
25. Clean the rear wheel bearings. Refer to Bearings Inspection Bearings Inspection.
26. Inspect the rear axle housing for the following conditions:

* Damaged threads
* Cracked welds
* Damaged flanges

Installation Procedure

1. Install the differential carrier. Refer to Differential Replacement Differential Replacement.
2. Lift the differential carrier, then lower the carrier onto the rear axle housing. Use a chain lift or equivalent.
3. Install the rear axle housing to the rear suspension.




4. Support the rear axle housing using a hydraulic transmission dolly with adapters in order to properly handle the rear axle housing.
5. Fasten a chain over the top of the rear axle housing and to both sides of the dolly.
6. Install the rear spring anchor plate bracket.
7. Install the rear shock absorber lower bracket, if equipped.





Notice: Refer to Fastener Notice in Cautions and Notices.

8. Install the following components:

* The rear spring U-bolts
* The washers
* The nuts

* In order to properly tighten the rear spring U-bolt nuts, torque the nuts progressively using the following steps:
* Tighten the rear spring U-bolt (20 mm [0.79 in] OD).

1. Tighten the rear spring U-bolt nuts to 100 Nm (74 lb ft).
2. Tighten the rear spring U-bolt nuts to 250 Nm (184 lb ft).
3. Tighten the rear spring U-bolt nuts to 388 Nm (287 lb ft).

Tighten the rear spring U-bolt (22 mm [0.87 in] OD).

1. Tighten the rear spring U-bolt nuts to 150 Nm (111 lb ft).
2. Tighten the rear spring U-bolt nuts to 275 Nm (203 lb ft).
3. Tighten the rear spring U-bolt nuts to 437 Nm (344 lb ft).

9. Install the rear shock absorber to the rear shock absorber lower bracket.

Tighten the rear shock absorber lower nuts to 84 Nm (62 lb ft).

10. Install the rear axle stabilizer shaft to the axle housing, if equipped. Refer to Stabilizer Shaft Replacement Rear Suspension.

Tighten the rear axle stabilizer shaft nuts to 240 Nm (177 lb ft).

11. Install the rear suspension control arms (air suspension only). Refer to Torque Rod Replacement Rear Suspension in Rear Suspension.

Tighten the rear suspension control arm nuts to 241 Nm (178 lb ft).

12. Install the rear axle tie rod, if equipped.

* Tighten the rear axle tie rod nuts (with air suspension) to 508 Nm (375 lb ft).
* Tighten the rear axle tie rod nuts (except air suspension) to 298 Nm (220 lb ft).

13. Install the differential lock air line, if equipped.
14. Install the two speed rear axle shift motor, if equipped. Refer to Two Speed Rear Axle Shift Motor Replacement (HPZ) Two Speed Rear Axle Shift Motor Replacement (HPZ)Two Speed Rear Axle Shift Motor Replacement (HR2) Two Speed Rear Axle Shift Motor Replacement (HR2).
15. Install the wiring to the rear axle housing.
16. Install the rear brake assembly, if equipped. Refer to Rear Cam Brake Assembly Replacement in Air Drum
17. Install the rear brake caliper mounting plates, if equipped. Refer to Brake Caliper Mounting Plate Replacement (Front, Bendix) Brake Caliper Mounting Plate Replacement (Front, Dayton-Walther) Brake Caliper Mounting Plate Replacement (Rear, Bendix Rail Slider) Brake Caliper Mounting Plate Replacement (Rear, Dayton-Walther Rail) in Disc Brakes.
18. Install the propeller shaft. Refer to the following procedures:

* Propeller Shaft Replacement - One Piece - Flange Type Propeller Shaft Replacement - One Piece - Flange Type
* Propeller Shaft Replacement - One-Piece - Yoke Type Propeller Shaft Replacement - One-Piece - Yoke Type
* Propeller Shaft Replacement - Two Piece - Flange Type Propeller Shaft Replacement - Two Piece - Flange Type
* Propeller Shaft Replacement - Two Piece - Yoke Type Propeller Shaft Replacement - Two Piece - Yoke Type
* Propeller Shaft Replacement - Three Piece - Flange Type Propeller Shaft Replacement - Three Piece - Flange Type
* Propeller Shaft Replacement - Three Piece - Yoke Type Propeller Shaft Replacement - Three Piece - Yoke Type
* Tandem Axle Propeller Shaft Replacement Tandem Axle Propeller Shaft Replacement

19. Install the rear axle lubricant. Refer to Lubricant Change Service and Repair.
20. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Disc Type-Single Front/Rear) Tire and Wheel Removal and Installation (Disc Type-Single Front/Rear)Tire and Wheel Removal and Installation (Disc Type-Dual) Tire and Wheel Removal and Installation (Disc Type-Dual)Tire and Wheel Removal and Installation (Cast Type-Single Front/Rear) Tire and Wheel Removal and Installation (Cast Type-Single Front/Rear)Tire and Wheel Removal and Installation (Cast Type-Dual) Tire and Wheel Removal and Installation (Cast Type-Dual) in Tires and Wheels.
21. Install the Axle Shaft, Drum, Hub, Hub/Rotor. Refer to following procedures:

* Rear Hub and Bearing Replacement Rear Hub and Bearing Replacement
* Brake Drum Replacement
* Rear Axle Shaft and/or Gasket Replacement Service and Repair

22. Check for air leaks. Refer to Air Brake System Leak Test in Air Brake.
23. Remove the supports from under the frame rails and lower vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.
24. Verify proper operation of the brakes.
25. Remove the wheel blocks.

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