Rear Axle Housing Cover and Gasket Replacement 8.6, 9.5 Inch Axle

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug.
4. Remove the rear axle housing cover bolts.

Discard the rear axle housing cover bolts.

5. Carefully remove the rear axle housing cover from the axle housing and drain the lubricant into a suitable container.
6. Remove any gasket material from the rear axle housing and/or the rear axle housing cover.
7. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation may be a indication of extreme wear.

1. Install the rear axle housing cover and a new gasket onto the axle housing.

Caution: Refer to Fastener Caution in the Preface section.

Note: Do not reuse the rear axle housing cover bolts

2. Install the new rear axle housing cover bolts and tighten in a crosswise pattern to 40 N·m (30 lb ft).
3. Fill the rear axle using the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
4. Install the rear axle fill plug and tighten to 33 N·m (24 lb ft).
5. Remove the support and lower the vehicle.

Rear Axle Housing Cover and Gasket Replacement 9.75, 10.5 and 10.75 Inch Axles

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Clean the area around the rear axle fill plug.
3. Remove the rear axle fill plug.



4. Remove the rear axle housing cover bolts.

Discard the rear axle housing cover bolts.

5. Carefully remove the rear axle housing cover from the axle housing and drain the lubricant into a suitable container.
6. Remove any sealant from the rear axle housing and/or the rear axle housing cover.
7. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation may be a indication of extreme wear.

1. Apply an approximately 3.18-6.35 mm (1/8-1/4 in) high and 3.18-6.35 mm (1/8-1/4 in) wide bead of sealant, GM P/N 12346240 (Canadian P/N 10953493) or equivalent, to the rear axle housing cover.

The sealant is to be applied in the middle of the rear axle housing cover flange and on the inside of all bolt hole openings as shown.




2. Install the rear axle housing cover.

Caution: Refer to Fastener Caution in the Preface section.

Note: Do not reuse the rear axle housing cover bolts.

3. Install the new rear axle housing cover bolts and tighten to 61 N·m (45 lb ft).

Note: Allow the sealant to cure for 1 hour before filling the axle with axle lubricant.

4. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations.
5. Install rear axle fill plug and tighten to 33 N·m (24 lb ft).
6. Lower the vehicle.