GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Express - AWD 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Rear Axle Housing Replacement

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Drain the axle lubricant. Refer to Rear Axle Lubricant Replacement .
  3. Remove the rear axle assembly. Refer to Rear Axle Replacement .
  4. Remove the brake caliper brackets. Refer to Rear Brake Caliper Bracket Replacement .
  5. Remove the brake rotors. Refer to Rear Brake Rotor Replacement .
  6. Remove the hub and rotor assembly, 10.5 and 10.75 inch axles only. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement .
  7. Remove the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  8. Remove the axle shafts. Refer to Rear Axle Shaft Replacement .
  9. Remove the brake backing plates. Refer to Rear Disc Brake Backing Plate Replacement .
  10. Remove the rear axle shaft oil seal and the bearing. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  11. Remove the differential assembly. Refer to Differential Replacement .
  12. Remove the drive pinion shaft yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  13. Remove the drive pinion and the inner pinion bearing. Refer to Drive Pinion and Ring Gear Replacement .
  14. Remove the pinion bearing cups. Refer to Drive Pinion Bearings Replacement .

Installation Procedure
  1. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement .
  2. Install the outer pinion bearing into the axle housing.
  3. Install the drive pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  4. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment .
  5. Install the selective shim onto the drive pinion.
  6. Install the inner pinion bearing onto the drive pinion. Refer to Drive Pinion Bearings Replacement .
  7. Install the drive pinion. Refer to Drive Pinion and Ring Gear Replacement .
  8. Install the drive pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  9. Install the differential assembly. Refer to Differential Replacement .
  10. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .
  11. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment .
  12. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
  13. Install the brake backing plates. Refer to Rear Disc Brake Backing Plate Replacement .
  14. Install the hub and rotor assembly, 10.5 and 10.75 inch axles only. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement .
  15. Install the rear axle shaft bearing and the oil seal. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  16. Install the axle shafts. Refer to Rear Axle Shaft Replacement .
  17. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  18. Install the brake rotors. Refer to Rear Brake Rotor Replacement .
  19. Install the brake caliper brackets. Refer to Rear Brake Caliper Bracket Replacement .
  20. Install the rear axle assembly. Refer to Rear Axle Replacement .
  21. Fill the axle with lubricant. Refer to Rear Axle Lubricant Replacement .
  22. Lower the vehicle.