Front Axle Gearbox — 2500 Series (Chevrolet Tahoe 2)

Removal

1. Turn the steering wheel all the way to the left.

2. Raise the car.

3. Move the jack to the rear of the frame.

4. Remove the engine protection.

5. If installed, remove the front axle gearbox guard.

6. Drain the oil from the gearbox.

7. Disconnect the front driveshaft from the gearbox.

8. Remove the tie rod.

9. Place a jack under the gearbox housing as a temporary support.

10. Unscrew the bolts securing the drive shafts of the wheels from both axle shafts.



11. On models with a disengageable axle, disconnect the axle engagement actuator wiring connector.



12. On models with a disconnectable axle, release the axle engagement actuator wires from the support clips on the axle beam.





13. On models with a disengageable axle, release the axle engagement drive wires from the support clips on the gearbox housing.



14. Disconnect the breather hose from the gearbox.



15. Unscrew the nuts securing the bridge beam to the bracket.



16. Unscrew the bolt and nut securing the upper support of the gearbox housing.





17. Rotate the gearbox housing on the lower support bolt down and outward until the weight of the gearbox is supported by the jack.

18. Secure the gearbox housing to the jack.

19. Remove the gearbox lower support bolt and nut.



20. Remove the gearbox housing.

Installation

1. Move the gearbox housing to the installation location.

2. Install the bolt and nut of the lower gearbox support, tighten the nut by hand.

3. Turn the gearbox housing on the lower support bolt up and in until the upper support bolt can be installed.

4. Install the upper support bolt and nut.

5. Install the washers and nuts securing the gearbox to the bracket. Tighten the bracket nuts, then the bolts and nuts of the upper and lower gearbox supports. Tightening torque 100 N·m.



6. Connect the breather hose to the gearbox housing.

7. Remove the temporary gearbox support.

8. Connect the bridge actuator wiring connector.

9. On models with a disconnectable bridge, secure the bridge engagement drive wires to the support clips.

10. On models with a disconnectable axle, connect the drive connector.

11. Connect the wheel drive shafts to the axle shafts. Tighten the mounting bolts. Tightening torque 80 Nm.

12. Install the tie rod.

13. Connect the front propeller shaft to the gearbox housing.

14. Fill the gearbox housing with transmission oil.

15. Install the gearbox protection.

16. Install the engine protection.

17. Remove the rear frame support jack.

18. Lower the vehicle.