GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Astro - 2WD 🢒 General Information 🢒 Vibration Diagnosis and Correction 🢒 Rear Axle Shaft Replacement

Removal Procedure

    Object Number: 156409 Size: SH
  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 drums.
  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. 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 lock (1) until the lock aligns with the thrust block (2).

    9. Object Number: 391222 Size: SH
  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).

Installation Procedure

    Object Number: 391222 Size: SH

    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. On axles with a locking differential, keep the pinion shaft partially withdrawn.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 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 25 N·m (19 lb ft).

  9. Install the rear cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  10. Install the brake drums.
  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 Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  13. Lower the vehicle.