Rear Axle Housing Replacement (G86)

Single Use Fasteners and Components Differential Carrier Bushing Differential Carrier Front Bolt Differential Drive Pinion Gear Bearing Spacer Differential Drive Pinion Gear Nut Differential Drive Pinion Gear Seal Rear Axle Shaft Seal [2x] Special Tools DT-22888-20A Universal Two Jaw Puller DT-22912-B Bearing Remover DT-24384-A Oil Seal Installer DT-3289-20 Holding Fixture DT-36597 Side Bearing Puller Pilot - 9.25 Inch DT-44412 Pinion Bearing Installer DT-52506 Pinion Flange Holder and Remover DT-52896 Pinion Seal and Side Bearing Installer DT-52898 Pinion Bearing Cup Installer DT-52900 Rear Cover Spreader Assembly DT-52902 Rear Drive Module Rotating Fixture DT-52903 Axle Flange Remover DT-5590 Bearing and Seal Driver GE-02619-A Slide Hammer w/Adapter Equivalent regional tools: Special Tools Removal Procedure

1. Remove the spare tire.
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Rear Axle Housing Replacement (G86) — figure 1

3. Position a drain pan under the rear differential carrier (1).
4. Rear Axle Housing Drain Plug (2) » Remove
5. Clean the rear axle housing drain plug. Allow the fluid to completely drain.

Caution

Refer to Component Fastener Tightening Caution.

6. Rear Axle Housing Drain Plug (2) » Install and tighten — Fastener Specifications

Rear Axle Housing Replacement (G86) — figure 2

7. Rear Propeller Shaft Bolt (1) » Remove [4x]

Rear Axle Housing Replacement (G86) — figure 3

8. Propeller Shaft (1) » Remove

Rear Axle Housing Replacement (G86) — figure 4

9. Rear Wheel Drive Shaft Bolt (1) » Remove [8x]
10. Reposition the right rear wheel drive shaft downward.

Rear Axle Housing Replacement (G86) — figure 5

11. Rear Wheel Drive Shaft Bolt (1) » Remove [8x]
12. Reposition the left rear wheel drive shaft downward.

Rear Axle Housing Replacement (G86) — figure 6

13. {If equipped} with dual exhaust. 13.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 13.2. Spare Wheel Heat Shield (1) » Remove

Rear Axle Housing Replacement (G86) — figure 7

14. {If equipped} with single exhaust. 14.1. Spare Wheel Heat Shield Bolt (2) » Remove [3x] 14.2. Spare Wheel Heat Shield (1) » Remove

Rear Axle Housing Replacement (G86) — figure 8

15. Rear Axle Vent Hose (2) » Disconnect
16. Support the rear differential carrier.

Rear Axle Housing Replacement (G86) — figure 9

17. Differential Carrier Nut (2) » Remove
18. Differential Carrier Front Bolt (1) » Remove and DISCARD

Rear Axle Housing Replacement (G86) — figure 10

19. Differential Carrier Rear Bolt (1) » Remove [2x]
20. Lower the rear differential carrier.

Rear Axle Housing Replacement (G86) — figure 11

21. Install the DT-52902 Rear Drive Module Rotating Fixture (2) to the rear axle housing and attach to the DT-3289-20 Holding Fixture (1).

Rear Axle Housing Replacement (G86) — figure 12

22. Using DT-52903 Axle Flange Remover (2) and GE-02619-A Slide Hammer w/Adapter (1), Remove the rear axle shaft (3).

Rear Axle Housing Replacement (G86) — figure 13

23. Rear Axle Shaft Seal (1) » Remove and DISCARD

Rear Axle Housing Replacement (G86) — figure 14

24. Using DT-52903 Axle Flange Remover (2) and GE-02619-A Slide Hammer w/Adapter (3), Remove the rear axle shaft (1).

Rear Axle Housing Replacement (G86) — figure 15

25. Rear Axle Shaft Seal (1) » Remove and DISCARD

Rear Axle Housing Replacement (G86) — figure 16

26. Rear Axle Housing Cover Bolt (1) » Remove [8x]
27. Rear Axle Housing Cover Bolt (2) » Remove [4x]

Rear Axle Housing Replacement (G86) — figure 17

28. Using the DT-52900 Rear Cover Spreader Assembly (2), Remove the rear axle housing (1).

Rear Axle Housing Replacement (G86) — figure 18

29. Remove the differential (3), spacers (2), and shims (1).

Rear Axle Housing Replacement (G86) — figure 19

30. Using DT-22888-20A Universal Two Jaw Puller (1) and DT-36597 Side Bearing Puller Pilot - 9.25 Inch (2), Remove the 2 differential bearings (3).

Rear Axle Housing Replacement (G86) — figure 20

31. Using DT-52506 Pinion Flange Holder and Remover (2), Remove and DISCARD the differential drive pinion gear nut (1).

Rear Axle Housing Replacement (G86) — figure 21

Note

Be careful not to damage the slinger when removing the pinion gear yoke assembly.

32. Using DT-52506 Pinion Flange Holder and Remover (2), Remove the differential drive pinion gear yoke (1).

Rear Axle Housing Replacement (G86) — figure 22

33. Differential Drive Pinion Gear Seal (1) » Remove and DISCARD

Rear Axle Housing Replacement (G86) — figure 23

34. Differential Drive Pinion Gear Outer Bearing (1) » Remove

Rear Axle Housing Replacement (G86) — figure 24

35. Differential Drive Pinion Gear (1) » Remove

Rear Axle Housing Replacement (G86) — figure 25

36. Differential Drive Pinion Gear Bearing Spacer (1) » Remove and DISCARD

Rear Axle Housing Replacement (G86) — figure 26

37. Using DT-22912-B Bearing Remover (1), Remove the differential drive pinion gear inner bearing (2).

Rear Axle Housing Replacement (G86) — figure 27

38. Differential Bolt (1) » Remove
39. Rear Axle Drive Pinion Oil Baffle (2) » Remove

Rear Axle Housing Replacement (G86) — figure 28

40. Rear Axle Housing Fill Plug (1) » Remove

Rear Axle Housing Replacement (G86) — figure 29

41. Rear Axle Housing Drain Plug (1) » Remove Cleaning and Inspection Procedure - Required
42. Clean any debris and material from the axle housing.
43. Inspect the axle components for damage and burrs, if any damage or burrs are found replacement of the affected axle components would be necessary.
44. Clean off the old sealant from the rear axle housing and rear axle housing cover using Acetone, followed by Isopropyl Alcohol. Installation Procedure

Rear Axle Housing Replacement (G86) — figure 30

1. Using the DT-52899 Rear Drive Module Mount Bushing Replacer (2), Install NEW differential carrier bushing (1).

Caution

Refer to Component Fastener Tightening Caution.

2. Rear Axle Housing Drain Plug (1) » Install and tighten — Fastener Specifications

3. Rear Axle Housing Fill Plug (1) » Install and tighten — Fastener Specifications

4. Rear Axle Drive Pinion Oil Baffle (2) » Install

Caution

Refer to Fastener Caution.

5. Differential Bolt (1) » Install and tighten — Fastener Specifications

Rear Axle Housing Replacement (G86) — figure 31

6. Using DT-52898-4 (3), DT-52898-1 (4), and DT-52898-5 (2), Install the differential drive pinion inner bearing cup (1).

Rear Axle Housing Replacement (G86) — figure 32

7. {If 9.5 inch RDM} Using DT-52898-1 (4), DT-52898-2 (3), and DT-52898-5 (2), Install the differential drive pinion outer bearing cup (1).
8. {If 9.76 inch RDM} Using DT-52898-1 (4), DT-52898-3 (3), and DT-52898-5 (2), Install the differential drive pinion outer bearing cup (1).

Rear Axle Housing Replacement (G86) — figure 33

9. Measure the thickness needed for the differential drive pinion bearing shims, refer to Pinion Depth Adjustment.

10. Using DT-44412 Pinion Bearing Installer (1), Install differential drive pinion gear inner bearing  (2) onto the differential drive pinion gear with the appropriate shim.

11. Differential Drive Pinion Gear Bearing Spacer (1) » Install NEW

12. Differential Drive Pinion Gear Outer Bearing (1) » Install

Rear Axle Housing Replacement (G86) — figure 34

13. Using DT-52896 Pinion Seal and Side Bearing Installer (1) , Install NEW differential drive pinion gear seal (2).

14. Differential Drive Pinion Gear (1) » Install

15. Apply sealant to the pinion yoke splines. Adhesives, Fluids, Lubricants, and Sealers

16. Apply grease to the pinion seal where it will contact the pinion gear yoke slinger. Adhesives, Fluids, Lubricants, and Sealers

Rear Axle Housing Replacement (G86) — figure 35

Note

Be careful not to damage the slinger when installing the pinion gear yoke assembly.

17. Differential Drive Pinion Gear Yoke (1) » Install

Caution

Refer to Torque-to-Yield Fastener Caution.

18. Using DT-52506 Pinion Flange Holder and Remover (2), Install NEW and tighten the differential drive pinion gear nut (1). Fastener Specifications

Rear Axle Housing Replacement (G86) — figure 36

19. Using DT-52896 Pinion Seal and Side Bearing Installer (1) and a shop press, Install NEW 2  differential bearing (2).

20. Measure the thickness needed for the differential bearing shims, refer to Differential Carrier Bearing Preload Adjustment.

21. Measure and adjust the backlash, refer to Backlash Adjustment.

22. Place the spacers (2) and shims (1) on the ends of the differential (3) and set the differential assembly into the rear axle housing.

Note

A dead blow hammer can be used to help seat the differential and shim.

23. Install the differential (3), spacers (2), and shims (1).

Rear Axle Housing Replacement (G86) — figure 37

Note

Install and align the rear axle housing within 10 minutes of applying sealer.

24. Apply a 4 mm (0.157 in) wide bead of sealant to the rear axle housing per the template above. Adhesives, Fluids, Lubricants, and Sealers The bead should be 2 mm (0.079 in) high and 2 mm (0.079 in) from the chamfer.

25. Using the DT-52900 Rear Cover Spreader Assembly (2), Install the rear axle housing (1).

26. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 26.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 26.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 26.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 26.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

27. Rear Axle Housing Cover Bolt (2) » Install and tighten [4x] — Fastener Specifications

28. Rear Axle Housing Cover Bolt (1) » Install and tighten [8x] — Fastener Specifications

Rear Axle Housing Replacement (G86) — figure 38

29. Remove (wipe out) excess sealant from the seal bore and deflector groove at the locations indicated by arrows, before installing the rear axle shaft seal.
30. Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (1), Install NEW rear axle shaft seal (2).

Rear Axle Housing Replacement (G86) — figure 39

31. Rear Axle Shaft (1) » Install

Rear Axle Housing Replacement (G86) — figure 40

32. Remove (wipe out) excess sealant from the seal bore and deflector groove at the locations indicated by arrows, before installing the rear axle shaft seal.
33. Using the DT-24384-A Oil Seal Installer and DT-5590 Bearing and Seal Driver (2), Install NEW rear axle shaft seal (1).

Rear Axle Housing Replacement (G86) — figure 41

34. Rear Axle Shaft (1) » Install

35. Remove the DT-52902 Rear Drive Module Rotating Fixture (2).

36. Raise the differential carrier.

37. Differential Carrier Rear Bolt (1) » Install and tighten [2x] — Fastener Specifications

Caution

Refer to Torque-to-Yield Fastener Caution.

38. Differential Carrier Front Bolt (1) » Install NEW

39. Differential Carrier Nut (2) » Install and tighten — Fastener Specifications

40. Remove support from the rear differential carrier.

41. Rear Axle Vent Hose (2) » Connect

42. {If equipped} with dual exhaust. 42.1. Spare Wheel Heat Shield (1) » Install 42.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

43. {If equipped} with single exhaust. 43.1. Spare Wheel Heat Shield (1) » Install 43.2. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

44. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 44.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 44.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 44.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 44.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

45. Reposition the right rear wheel drive shaft.

46. Rear Wheel Drive Shaft Bolt (1) » Install and tighten [8x] — Fastener Specifications

47. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 47.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 47.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 47.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 47.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

48. Reposition the left rear wheel drive shaft.

49. Rear Wheel Drive Shaft Bolt (1) » Install and tighten [8x] — Fastener Specifications

50. Propeller Shaft (1) » Install

51. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 51.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 51.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 51.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 51.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

52. Rear Propeller Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

Rear Axle Housing Replacement (G86) — figure 42

53. Rear Axle Housing Fill Plug (1) » Remove
54. Fill the rear differential carrier with the appropriate amount and type of axle lubricant: Adhesives, Fluids, Lubricants, and Sealers Approximate Fluid Capacities
55. The gear lubricant level should be 0 - 5 mm (0.0 - 0.20 in) below the bottom of the fill plug opening.
56. Rear Axle Housing Fill Plug (1) » Install and tighten — Fastener Specifications
57. Remove the support and lower the vehicle.
58. Install the spare tire.