GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Astro - 4WD 🢒 Driveline/Axle 🢒 Rear Drive Axle 🢒 Rear Axle Housing Replacement

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  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 in Disc Brakes.
  5. Remove the brake rotors. Refer to Rear Brake Rotor Replacement in Disc Brakes
  6. Remove the rear axle cover housing and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  7. Remove the axle shafts. Refer to Rear Axle Shaft Replacement .
  8. Remove the brake backing plates. Refer to Rear Disc Brake Backing Plate Replacement in Disc Brakes.
  9. Remove the rear axle shaft oil seal and the bearing. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  10. Remove the differential assembly. Refer to Drive Pinion and Ring Gear Replacement .
  11. Remove the drive pinion shaft yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  12. Remove the drive pinion and the inner pinion bearing. Refer to Drive Pinion and Ring Gear Replacement .
  13. 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 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 pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement .
  9. Install the differential assembly. Refer to Drive Pinion and Ring Gear Replacement .
  10. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment .
  11. Adjust the 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 in Disc Brakes.
  14. Install the rear axle shaft oil seal and the bearing. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  15. Install the axle shafts. Refer to Rear Axle Shaft Replacement .
  16. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  17. Install the brake rotors. Refer to Rear Brake Rotor Replacement in Disc Brakes
  18. Install the brake caliper brackets. Refer to Rear Brake Caliper Bracket Replacement in Disc Brakes.
  19. Install the rear axle assembly. Refer to Rear Axle Replacement .
  20. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement .
  21. Lower the vehicle.