Chevrolet 25903653 Rear Axle Assembly (4.10 Ratio)

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To install the semi-floating axle shaft, you should insert the axleshaft into the housing until it engages with the differential side gear, install the C-lock, and insert the pinion shaft. Then, install the cover, fill the differential with lubricant, and install the brake disc or drum.

The initial steps to remove and install components in the front differential of selectable 4WD systems are as follows: Loosen the wheel lug nuts. Raise the vehicle securely on jackstands. Remove the right front wheel. Remove the differential carrier splash shield if equipped. Drain the lubricant from the front differential. For 4WD systems, unbolt the right driveaxle from the axleshaft flange and support it out of the way. Remove the front axle shift motor and, if applicable, disconnect the front stabilizer link or remove the front shock absorber/coil spring assembly. On 2500/3500 models, remove the front axle bracket bolts and slide the bracket forward for additional clearance. Support the differential carrier with a floor jack and a block of wood.

For coil spring models, the links for the electronic suspension control sensors should be detached, followed by detaching the track bar from the rear axle. The stabilizer bar, coil springs, and upper and lower trailing arms should be disconnected from the axle assembly. Finally, the jack can be lowered under the differential to remove the rear axle assembly.

The outer ends of the driveaxles are equipped with ball-and-cage type CV joints capable of angular but not axial movement.

4WD models use a fully independent front axle assembly.

The final step is to tighten the wheel lug nuts to the proper torque specifications.

If a boot is damaged, the CV joint can be disassembled and cleaned, but if any parts are damaged, the entire driveaxle assembly must be replaced as a unit.

After raising the vehicle and supporting it on jackstands, a jack should be positioned under the rear axle differential housing.

Before installing the driveaxle, the splines on the stub shaft should be lubricated with multi-purpose grease.

To remove and install components in the front differential for 4WD systems, follow these steps: Remove the bolts securing the axle tube to the differential carrier and the nuts attaching the tube to its support bracket. Carefully remove the output shaft tube, ensuring no components fall out. Mount the tube in a vise and remove the internal components. Measure and remove the axleshaft bearing using a slide hammer and bearing remover attachment. For installation, install the bearing to the original depth using a bearing driver or socket, then install a new seal and deflector, lubricating the seal lips with grease. Carefully drive in the axleshaft, followed by the internal components. Apply RTV sealant to the tube-to-differential housing mating surface, and install the tube assembly, tightening bolts and nuts to specified torques. Reinstall the driveaxle, front axle shift motor, and fill the differential with lubricant.

After installing the rear axle assembly, the brakes should be bled, the wheels and lug nuts should be installed, and the vehicle should be lowered. Finally, the lug nuts should be tightened to the proper torque specification.

For models with a locking differential, you should rotate the differential until the shaft touches the case for access to the C-locks.

The differential allows the outer rear wheel to turn at a higher speed than the inner tire when going around a corner.

After removing the differential cover, you need to remove the pinion shaft lock screw and withdraw the pinion shaft.

If a boot is damaged, the CV joint can be disassembled and cleaned, but if any parts are damaged, the entire driveaxle assembly must be replaced as a unit.

After raising the vehicle and securing it on jackstands, you should pry off the hub cover and remove the driveaxle/hub nut while bracing the hub to prevent it from rotating.

4WD models use a fully independent front axle assembly.

To remove and install components in the front differential for AWD systems, follow these steps:Remove the stabilizer bar link and, if applicable, the front shock absorber.

Before removing the rear axle assembly, the following components need to be removed: driveshaft, shock absorbers, vent hose, brake hose, rear brake assemblies, parking brake cables, and rear wheel speed sensors.

To remove and install components in the front differential for 4WD systems, follow these steps: Remove the bolts securing the axle tube to the differential carrier and the nuts attaching the tube to its support bracket. Carefully remove the output shaft tube, ensuring no components fall out. Mount the tube in a vise and remove the internal components. Measure and remove the axleshaft bearing using a slide hammer and bearing remover attachment. For installation, install the bearing to the original depth using a bearing driver or socket, then install a new seal and deflector, lubricating the seal lips with grease. Carefully drive in the axleshaft, followed by the internal components. Apply RTV sealant to the tube-to-differential housing mating surface, and install the tube assembly, tightening bolts and nuts to specified torques. Reinstall the driveaxle, front axle shift motor, and fill the differential with lubricant.

4WD models use a fully independent front axle assembly.

To check for wear in the CV joints and driveaxle shafts, grasp each axle and rotate it in both directions while holding the CV joint housings, feeling for play indicating worn splines or sloppy CV joints.

To remove the semi-floating axle shaft, you need to remove the C-lock from the groove on the inner end of the axleshaft and withdraw the shaft, being careful not to damage the oil seal.

The driveaxle/hub nut (new) and the flange bolts should be tightened to the torque values specifications during installation.