Several posters have asked if anyone has posted the procedure for changing the rear axle/hub seal on a 2500HD. I never found any with pictures.
I did mine, a 2002, and took the time to document the entire process. I just passed 100K miles and this is the second seal replacement. I had posted this earlier with a link to another website. The moderators asked that it be reposted in this format, so here we go:
This is what you'll need: Seal, wheel bearing locknut socket ($10.00), and brake cleaner (multiple cans, I used 3). I got the stuff at O'Reilly's.
Here is a close up of the locknut wrench.
Here is the seal that is listed on the O'Reilly's computer, it is not the right one.
Here is what the wrong seal looks like.
Remove the 8 bolts that hold the axle with a 3/4 socket, then carefully remove the axle. It has a gasket on it that you don't want to tear.
Here is the axle after removal.
Here is the hub after the removal of the axle.
Remove the caliper. It took an 18mm socket. Leave the brake line attached.
Remove the rotor. It just pulls off.
You are now down to the hub, and you can see the parking brake shoes which are likely to be covered with gearlube.
Here is another shot of the parking brake.
Remove the snap ring. No special tools are required.
The snap ring keeps the key for the axle nut in place.
Remove the key. It just slides out.
Here is the axle nut after removal with the special socket.
Here is the spindle with the emergency brake after the removal of the hub. The hub just pulls off.
I used a brake adjustment tool to pry out the seal. Seal pullers can be purchased.
Remove the seal with very small and careful prying, turning frequently.
Here is the hub with the seal ready to come out.
Here is the hub with the seal removed.
As mentioned earlier, O'Reilly's lists the wrong seal. On the right is the one they list, and the on the left is the removed seal. The correct seal is 3 and 15/16 inches in diameter.
Here is a good thing to have available when you have to go back to O'Reilly's.
Here is the correct seal from O'Reilly's. It was listed for a 2000 2500HD.
This is the brand of the seal.
I used a piece of wood to protect the seal as I tap it in place carfully with a hammer.
Here is the new seal installed in the hub.
The rotors are vented. It is likely that you will have gear lube on the rotor, inside the emergency brake surface, and inside the vents of the rotor.
It took a lot of work to get the rotor clean. The key to cleaning a heavy build up of gearlube is to have scraping tools, several cans of brake cleaner, and lots of paper towels. Wet with brake cleaner, wipe, and get a clean towel. If you don't change paper towels often, you'll just smear gearlube over the same areas, over and over.
I keep hand cleaner handy, especially during re-installation. Keep your hands clean and you'll keep the rotor, shoes, and pads clean.
Slide the hub back on the spindle.
Start screwing the hub locknut back on.
You'll use a torque wrench and the special axle nut socket. (Yeah, I know, it's one of those old beam type torque wrenches, but I'm an old guy.) Torque to approximately 50 ft lbs while rotating the hub counter-clockwise. This seats the hub.
After seating the hub. Loosen the axle nut, adjust it finger tight and align it so you can slip in the locking key that keeps the nut from moving.
Re-install the snap ring to hold the key.
Slide the cleaned rotor back on making sure it is seated as pictured.
You are now ready to re-install the caliper.
Re-install the caliper. I used thread lock on these bolts.
Slide the axle back in after you clean it off. (just a wipe down will do) Re-install and tighten the 8 bolts. I used thread sealer on these too.