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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1037 (REAR DRIVE AXLE)REPAIR INSTRUCTIONSREAR AXLE HOUSING REPLACEMENTINSTALLATION PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Installation Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Installation Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the pinion bearing cups. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axles) Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  2. Install the outer pinion bearing into the axle housing.
  3. Install the drive pinion oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) .
  4. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6 Inch, 9.5 Inch, 11.5 Inch Axles)  or Pinion Depth Adjustment (9.75 Inch Axle)  or Pinion Depth Adjustment (10.5 Inch Axle) .
  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 (8.6, 9.5, 11.5 Inch Axles)  or Drive Pinion Bearings Replacement (9.75 Inch Axle)  or Drive Pinion Bearings Replacement (10.5 Inch Axle) .
  7. Install the drive pinion. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles)  or Drive Pinion and Ring Gear Replacement (9.75 Inch Axle)  or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) .
  8. Install the pinion yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle)  or Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch Axle) .
  9. Install the differential assembly. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles)  or Drive Pinion and Ring Gear Replacement (9.75 Inch Axle)  or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) .
  10. Adjust the differential side bearing preload. Refer to Differential Side Bearing Preload Adjustment (8.6 Inch Axle)  or Differential Side Bearing Preload Adjustment (9.5 Inch Axle)  or Differential Side Bearing Preload Adjustment (9.75 Inch Axle)  or Differential Side Bearing Preload Adjustment (10.5 Inch, 11.5 Inch Axles) .
  11. Adjust the drive pinion to ring gear backlash. Refer to Backlash Adjustment (8.6 Inch Axle)  or Backlash Adjustment (9.75 Inch Axle) .
  12. Perform a gear tooth contact pattern check. Refer to Gear Tooth Contact Pattern Inspection .
  13. Install the brake backing plates. Refer to Disc Brake Backing Plate Replacement - Rear (15 Series w/o NYS) or Disc Brake Backing Plate Replacement - Rear (25/35 Series) or Disc Brake Backing Plate Replacement - Rear (15 Series W/NYS) in Disc Brakes.
  14. For the 10.5 inch and 11.5 inch axles, install the hub/rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement .
  15. For the 8.6 inch and 9.5 inch axles, install the rear axle shaft bearing and the oil seal. Refer to Rear Axle Shaft Seal and/or Bearing Replacement .
  16. Install the axle shafts. Refer to Rear Axle Shaft Replacement (8.6 Inch, 9.5 Inch Axles)  or Rear Axle Shaft Replacement (9.75 Inch Axle) , 8.6 inch, 9.5 inch axles, or Rear Axle Shaft and/or Gasket Replacement , 10.5 inch, 11.5 inch axles.
  17. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement .
  18. For the 8.6 inch and 9.5 inch axles, install the brake rotors. Refer to Brake Rotor Replacement - Rear (Except Dual Wheels or NYS) or Brake Rotor Replacement - Rear (W/Dual Wheels) or Brake Rotor Replacement - Rear (W/NYS) in Disc Brakes
  19. Install the brake caliper brackets. Refer to Brake Caliper Bracket Replacement - Rear (15/25 Series w/o NYS) or Brake Caliper Bracket Replacement - Rear (35 Series) or Brake Caliper Bracket Replacement - Rear (15 Series w/NYS) in Disc Brakes.
  20. Install the rear axle assembly. Refer toRear Axle Replacement (15/25 Series)  or Rear Axle Replacement (35 Series)  or Rear Axle Replacement (15 Series with RPO NYS) .
  21. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.75 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.5, 10.5, and 11.5 Inch Axles) .
  22. Lower the vehicle.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.