Rear Axle Replacement (25 Series W/ RPO NYS)

Rear Axle Replacement (25 Series w/ RPO NYS)

Removal Procedure






1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Place jack stands at the front end of the vehicle in order to support the weight difference when the rear axle is removed.
3. Drain the axle lubricant from the rear axle.
4. Remove the propeller shaft.
5. Remove the tire and wheel assemblies.
6. Disconnect the parking brake cables.
7. Remove the left and right brake calipers from the brake caliper mounting brackets. Do not disconnect the hydraulic brake lines from the brake calipers. Secure the left and the right brake calipers with mechanics wire to the leaf spring or the frame assembly.






8. Remove the 2 flex hose bracket bolts (1).
9. Remove the 2 brake pipe bracket bolts (2).
10. Remove the jounce bracket bolt (3).
11. Remove the brake pipe bracket nut (4). Secure the rear brake pipe assembly with mechanics wire to the under body and frame. Do not bend or kink the brake pipe assembly.
12. Disconnect the shock absorbers from the axle brackets.
13. Remove the vent hose from the rear axle vent fitting.
14. Support the rear axle assembly with a suitable jack. Remove the nuts and the washers if equipped from the U-bolts.
15. Remove the U-bolts, the spring plates and the spacers from the axle assembly.
16. Lower the axle assembly.

Installation Procedure






1. Place the axle assembly onto the jack and place the rear axle assembly under the vehicle.
2. Align the rear axle assembly with the springs. Using the jack slowly raise the rear axle assembly into position.
3. Connect the spacers, the spring plates and the U-bolts to the rear axle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the washers if equipped and the nuts to the U-bolts.

Tighten
Tighten the nuts in a crisscross pattern to 150 Nm (110 ft. lbs.).

5. Install the vent hose to the rear axle vent fitting.
6. Connect the shock absorbers to the rear axle.






7. Remove the mechanics wire supporting the brake pipe assembly. Carefully position the brake pipe assembly onto the rear axle.
8. Install the brake pipe bracket nut (4).

Tighten
Tighten the nut to 13 Nm (115 inch lbs.).

9. Install the jounce bracket bolt (3).

Tighten
Tighten the bolt to 12 Nm (106 inch lbs.).

10. Install the 2 brake pipe bracket bolts (2).

Tighten
Tighten the bolts to 22 Nm (16 ft. lbs.).

11. Install the 2 flex hose bracket bolts (1).

Tighten
Tighten the bolts to 12 Nm (106 inch lbs.).

12. Remove the mechanics wire securing the brake calipers and install the brake calipers to the brake caliper mounting brackets.
13. Connect the parking brake cable.
14. Install the tire and wheel assemblies.
15. Connect the propeller shaft.
16. Fill the axle with lubricant. Use the proper fluid.
17. Remove the jack stands.
18. Lower the vehicle.