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NOTE: Unless noted, the procedures in this section apply to both the conventional differential and the Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential. The Model S135 rear axle features the following: a hypoid design differential ring gear and pinion a two-bearing overhung pinion mounting full-floating axle shafts a steel differential housing a front mounted removable one-piece carrier housing a conventional differential assembly or a Truetrac® limited slip differential assembly The trademark shows the company logo, and identifies the location of the manufacturing facility. CAUTION: Never mate a differential ring gear and pinion together that does not have the same matched set numbers. Always install a new matched set if discarding either the differential ring gear or the pinion. A corresponding number marked on the differential ring gear and pinion identifies them as a matched set. The manufacturer’s date identifies the gear set’s date of fabrication. The tooth combination identifies the number of teeth on the pinion and the number of teeth on the differential ring gear. A tooth combination of 41-11, for example, would indicate that the pinion has 11 teeth and the ring gear has 41 teeth that results in a 3.73:1 ratio. Dana Model S135 Full-Floating Rear Axle, Disassembled View

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1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-00. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-00. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the Specifications in this section. Item 2: Rear Disc Brake Caliper Removal Note 1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support. Position the rear disc brake caliper aside. For additional information, refer to Section 206-00. Item 7: Differential Pinion Shaft Removal Note 1. Move the differential pinion shaft out far enough to remove the U-washers. Replace the shaft and install the lock bolt finger tight when U-washers are removed. Item 8: U-washer Removal Note 1. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal Note 1. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 8.8 inch rear axle, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 9.75 inch and the 10.25 inch rear axles, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. Item 11: Axle Shaft Bearing Installation Note 1. For the 8.8 inch and the 9.75 inch rear axles, use the special tools to install the rear axle wheel bearing. 2. For the 10.25 inch rear axle, use the special tools shown to install the rear axle wheel bearing. Item 10: Wheel Bearing Oil Seal Installation Note 1. Use the special tools shown to install the rear wheel bearing oil seal. Item 8: U-washer Installation Note 1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1. Position the two U-washers on the button end of the axle shafts. 2. Pull the axle shafts outward.

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Removal NOTE: If, for any reason, the rear hub (1109) is removed from the spindle, the old hub seal must be removed and a new hub seal installed. 1. Set the parking brake and loosen the eight axle shaft retaining bolts. 2. Raise the vehicle to the desired working height, keeping the axle parallel with the floor. 3. Release parking brake and back off the rear brake adjustment, if necessary. 4. Remove the wheel (1007). 5. Remove brake drum (1126). Push-on (sheet metal) drum retainer nuts may be discarded. Push-on retainer nuts are used for shipping purposes only and have no vehicle function. If retainers are not flush against the drum, the retainers can prevent the wheel from being flat against the drum, which could contribute to vibration. 6. Place a drain pan under the axle shaft (4234) and rear hub. Remove the eight 7/16-inch axle shaft bolts and remove the axle shaft. Axle Shaft Removal 7. CAUTION: The right hub nuts are right-hand thread; the left hub nuts are left-hand thread. Each hub nut is stamped RH for the right hub nut or LH for the left hub nut. Install Locknut Wrench T85T-4252-AH so that the drive tangs of the tool engage the four slots in the hub nut. 8. CAUTION: A new hub nut must be installed if used hub nut comes apart during removal or installation. CAUTION: Under no circumstances are power impact tools to be used when performing these operations. NOTE: The hub nut will ratchet during this operation. Remove hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 9. Install Step Plate Adapter D80L-630-7 (Part of Step Plate Adapter Set D80L-630-A) or equivalent. 10. Install 2-Jaw Puller D80L-1002-L or equivalent and loosen rear hub to the point of removal. 11. CAUTION: Do not drop outer hub bearing when removing. Remove rear hub assembly.

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1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to Section 100-02. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-04. 3. Remove the brake drum. For additional information, refer to Section 206-02. 4. Remove the differential housing cover (4033) and drain the lubricant. Clean the gasket material from the differential housing cover and the differential housing (4010). 5. CAUTION: The differential assembly is equipped with either a Loctite® coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite® treated differential pinion shaft lock screw has a 5/32-inch hexagram socket head. Never, under any circumstance, reuse a Loctite® coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than four installations. When in doubt about the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new screw. Remove the lock screw. 6. Remove the differential pinion shaft (4211). The pinion shaft is a slip-fit design and is removable by hand. 7. Push the flanged end of the axle shaft (4234) toward the center of the axle and remove the U-washer (4N237).

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2011 model year Cadillac Escalade EXT; Chevrolet Avalanche, Silverado; and GMC Sierra vehicles. Some of these vehicles have a condition in which the rear axle cross pin was not manufactured to specification. The pin was improperly heat treated and could fracture and become displaced within the rear axle. If this were to occur, the driver may hear a banging noise coming from the axle. If the pin shifts out of position, it could create an interference condition and cause the rear axle to lock. The driver may not be able to maintain directional control of the vehicle and a crash could occur without prior warning. SERVICE PROCEDURE 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Shift the transmission into “N” Neutral. 3. FOR SUV ONLY: Remove the LH track bar attachment bolt using a 21 mm socket. 4. FOR SUV ONLY: Remove with a screwdriver the emergency brake cable clip from the track bar. 5. FOR SUV ONLY: Raise the track bar, hanging it with a hook to the frame. 6. Take the cover pan bolts off using a ratchet with a 13 mm socket. Hold the cover pan with your hand to drain the oil in a container. Dispose of the bolts. 7. When most of the oil is drained, remove cover pan and gasket. Store the cover pan and gasket in a secure area. 8. While holding one wheel, turn the other wheel until the lock screw is visible. 9. Remove the lock screw with a ratchet with a 5/16” hexagonal socket while holding the cross pin with a magnet. Dispose of the lock screw. 10. Remove the cross pin by pulling it with the magnet. Discard the cross pin. 11. Using a magnet, insert a new certified cross pin without moving the case position, aligning the cross pin hole with the lock screw hole. 12. Replace the lock screw with a new one and tighten by hand until it stops. Apply a static torque of 35 Nm (26 lb-ft) with a pre-set clicker wrench. Certify the torque applying a slash through the lock screw head and the differential case. 13. Visually inspect the gasket for damage and replace if necessary. 14. Position gasket and cover pan ensuring proper alignment making sure not to damage the gasket.