GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Tahoe - 2WD 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Rear Axle Shaft Replacement

Special Tools
    • J 2619-01 Slide Hammer W/ 1/2 x 13 Adapter
    • J 45859 Axle Shaft Remover/Installer

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 mounting bracket. Refer to Rear Brake Caliper Bracket Replacement.
  4. Remove the rear wheel speed sensor.
    5. • For the Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement.
    • For the non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement.
    • For the non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement.
  5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
  6. Remove the pinion shaft locking bolt.

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

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

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

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

    12. Object Number: 788488 Size: SH

    Note: 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.

  12. Remove the axle shaft from the housing.

    13. Object Number: 885619 Size: SH

    Note: Perform the following step if the axle shaft is hard to remove.

  13. Using the J 2619-01 slide hammer  (1) and the J 45859 remover/installer  (2)  to remove the axle shaft from the housing.

Installation Procedure

    Object Number: 788488 Size: SH
  1. Install the axle shaft into the rear axle housing, allowing the splines to engage the differential side gear.

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 On axles with a locking differential, keep the pinion shaft partially withdrawn.

    4. Object Number: 156412 Size: SH
  4. 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).
  5. Pull the shaft flange outward in order to seat the C-lock in the differential gear.

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

    7. Caution: Refer to Fastener Caution in the Preface section.

  7. Install the new pinion shaft locking bolt.
    8. • For the 8.6  inch axle, tighten the pinion shaft locking bolt to 36 N·m (27 lb ft).
    • For the 9.5 LD  inch axle, tighten the pinion shaft locking bolt to 50 N·m (37 lb ft).
  8. Install the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
  9. Install the brake caliper mounting bracket. Refer to Rear Brake Caliper Bracket Replacement.
  10. Install the rear wheel speed sensor.
    11. • For the Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement.
    • For the non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement.
    • For the non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
  12. Fill the rear axle with the proper axle lubricant. Refer to Rear Axle Lubricant Level Inspection.
  13. Lower the vehicle.