Axle Seal - Rear

This procedure covers the replacement of the rear axle seal on a 2023 Chevrolet Bolt EUV, requiring removal of the rear halfshaft and differential cover to access and replace the seal.

Warnings

Tools required

Parts

• Rear axle seal × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Axle nut cotter pin or stake washer × 1 — Use OEM specification

Fluids

• ACDelco Dexron VI ATF — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on the ground
4. Raise rear of vehicle and support securely on jack stands at manufacturer-designated lift points
5. Remove rear wheel on the side requiring seal replacement
6. Place drain pan under differential
7. Clean area around differential cover and axle seal to prevent contamination

Procedure

1. 1

   Remove axle nut
   Have an assistant apply the brake pedal or use a pry bar to prevent wheel hub rotation. Remove and discard the cotter pin or unstake the axle nut. Using a breaker bar and appropriate socket, remove the rear axle nut. This nut is torqued to 250 Nm and will require significant force to loosen.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
2. 2

   Disconnect CV joint from differential
   Locate the inner CV joint bolts connecting the halfshaft to the differential stub shaft. Mark the orientation of the CV joint flange to the differential flange for proper reassembly alignment. Remove all CV joint bolts and carefully support the halfshaft. Use wire or rope to support the outer end of the halfshaft to prevent damage to the CV boot.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
3. 3

   Remove differential cover
   Position drain pan directly under differential cover. Remove all differential cover bolts in a crisscross pattern, starting with the top bolts and leaving two lower bolts partially threaded. Once fluid begins draining, remove remaining bolts and carefully pry cover away from housing. Allow all fluid to drain completely into pan. Remove and discard old gasket material.
   ⚠Fluid will drain quickly once cover is loosened. Ensure drain pan is properly positioned.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
4. 4

   Clean differential housing mating surface
   Using a wire brush and brake cleaner, thoroughly clean the differential housing mating surface where the cover seals. Remove all old gasket material and RTV sealant. Ensure surface is completely clean and dry before proceeding. Also clean the differential cover mating surface in the same manner.
5. 5

   Remove old axle seal
   With the differential cover removed, the axle seal is now visible in the differential housing bore. Using a seal puller or appropriate seal removal tool, carefully extract the old axle seal from the housing. Take care not to damage the seal bore surface during removal. Inspect the bore for any scoring or damage that could cause the new seal to leak.
   ⚠Do not use sharp tools that could gouge the seal bore. Damage to the bore will cause the new seal to leak.
6. 6

   Prepare and install new axle seal
   Clean the seal bore thoroughly with brake cleaner and a lint-free rag. Inspect the seal bore for any damage. Lightly coat the outer diameter of the new seal with clean Dexron VI ATF. Position the seal squarely in the bore with the seal lip facing inward toward the differential. Using the appropriate size seal driver, carefully drive the seal into the bore until it is fully seated and flush with the housing face.
   ⚠Seal must be driven in straight and square to prevent damage. Use proper size driver that contacts only the outer edge of the seal.
7. 7

   Inspect halfshaft seal surface
   Thoroughly inspect the sealing surface on the halfshaft where it contacts the new seal. Look for grooves, scoring, or corrosion. Clean the seal contact area with brake cleaner. If the shaft shows wear in the seal contact area, the halfshaft should be replaced to prevent premature seal failure.
8. 8

   Install differential cover
   Apply RTV silicone gasket maker in a continuous bead to the differential housing mating surface, or install new gasket per manufacturer specification. Position the differential cover and install all cover bolts hand-tight. Torque the differential cover bolts in a crisscross pattern to specification to ensure even gasket compression and prevent leaks.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
9. 9

   Refill differential with fluid
   Locate the differential fill plug on the side of the housing. Remove the fill plug. Using a fluid pump or funnel with hose, add ACDelco Dexron VI ATF until fluid begins to run out of the fill hole. The differential is properly filled when fluid reaches the bottom of the fill plug opening. Install and tighten the fill plug.
10. 10

    Reinstall halfshaft to differential
    Lightly coat the seal lip of the new axle seal with clean Dexron VI ATF. Align the marks made during disassembly and carefully guide the halfshaft into the differential, taking care not to damage the new seal. Install all CV joint bolts and torque to specification in a star pattern.
    ⚠Insert halfshaft carefully to avoid cutting or rolling the new seal lip.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)
11. 11

    Install axle nut
    Install a new axle nut onto the halfshaft. Have an assistant apply the brake pedal or use a pry bar to prevent hub rotation. Torque the axle nut to specification. Install a new cotter pin through the castle nut and bend the ends to secure, or stake the nut per manufacturer specification.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Install the rear wheel and thread lug nuts by hand. Torque wheel lug nuts to specification in a star pattern. Lower vehicle to the ground and perform final torque check on lug nuts.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify differential is filled to proper level
3. Check for any fluid leaks around differential cover and new axle seal
4. Dispose of used differential fluid according to local environmental regulations

Verification

• Start vehicle and verify no warning lights related to drivetrain
• Test drive vehicle and listen for any abnormal noises from rear differential area
• After test drive, inspect differential cover and axle seal area for any signs of fluid leakage
• Re-check differential fluid level after test drive and top off if necessary
• Inspect again after 50-100 miles of driving to confirm seal is not leaking

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