2003 Yukon rear axle swap

[Saucy_Walnuts]

So a week or so ago I found out my rear pinion bearing is out or the rear gear set is just wore out. It's a 2003 GMC Yukon 4x4. I found and bought a 2001 Chevy Tahoe 4x4 rolling frame. Everything besides engine and transmission. It's exact same gearing 3:73s. I'll be doing the swap this Saturday. Changing fluid/seals while I'm at it. Probably most all rear suspension parts as well. Since they all look pretty much new. Is there anything else I should probably do while I'm there. Pic is of the roller frame and Ring gear from the roller.

 

[Saucy_Walnuts]

It is a big pain in the butt to change out if your by yourself and have only floor jacks and jack stands. It took 5hrs (granted mine was rusty as heck and a few bolts needed cut) including a few sanity breaks. But there were only a few tools needed. I didn't take any pics during the swap but did after. I'll do my best to give a step by step.

21mm deep socket
21mm Wrench
18mm deep socket
18mm wrench
11mm socket
13mm socket
14mm flare nut wrench (brake lines)
11mm wrench (for bleeding brakes)
Impact wrench (not required but a big help)
Small vice grips (pinching off brake line hose)

Once the SUV is jacked up put stands on the frame just in front of the axle maybe 8-10 inches. Remove the tires. Leave the jack under the diff (it will help you pull the axle out)

There are 2 21mm bolts on the passenger side upper and lower control arms. 1 18mm bolt on the lower shock. And 1 18mm bolt on the upper sway bar link. Once they are off move to the rear center control arm. There are 2 21mm bolts, one on the axle and one on the frame. You will need to remove the park brake cable from the the rear control arm there are two easy to remove clips. Once this is done the passenger side is done.

On the driver side the process is the same as the passenger other than needing to remove the parking brake cables. They can be removed by pinching the clips with a pair of pliers or a small screw driver and pulled out of the mount on the frame. Once this is done there are 4 11mm bolts on the drive shaft at the rear ujoint. Remove them and pop it off the pinion yoke. And move the drive shaft out of the way. You will then need to remove the brake lines from the top of the diff as well as a breather hose for the diff. The brake lines are a 14mm Flare nut wrench pinch the rubber brake line with the small vise grips. Once they are removed you can use a 13mm socket to remove the line from the top of the diff.

Once this is done you can drop the jack and the springs will fall free. Installing is the reverse order and 2 people are better than one when Installing the axle back in because it will need to be fanegled around to align the bolt holes. And brakes will need bled and fluid added as needed. I also did a complete service on the diff changing the oil and adding new 80-90 gear oil and a friction modifier for limited slips. I got a Fel-Pro 8.6inch gm 10bolt gasket. I'm also going to put new Ujoints on next weekend.

I did a test drive once everything was pit back together and checked all bolts to ensure they were still tight and no leaks were present.

The frame in the picture is one i purchased just for the rear axle and suspension parts. As well as a spare front axle suspension parts and drive shafts.

Im hoping i did a good write up on the process. I didnt think about getting pics as I was taking it out. And swapping the new one in.

 

[OBSandaNNBS]

So a week or so ago I found out my rear pinion bearing is out or the rear gear set is just wore out. It's a 2003 GMC Yukon 4x4. I found and bought a 2001 Chevy Tahoe 4x4 rolling frame. Everything besides engine and transmission. It's exact same gearing 3:73s. I'll be doing the swap this Saturday. Changing fluid/seals while I'm at it. Probably most all rear suspension parts as well. Since they all look pretty much new. Is there anything else I should probably do while I'm there. Pic is of the roller frame and Ring gear from the roller.

I'd say 5 hours without a lift and with axle service and taking breaks is doing pretty good

 

[Saucy_Walnuts]

I'd say 5 hours without a lift and with axle service and taking breaks is doing pretty good

I thought so. It's made multiple 5hr trips to Ottawa, Emporia, And Wichita for work with no issues at all. Next it will need the transfer case halfs re sealed.