I am trying to remove the rear axle and replace the seal on my 2004 Tahoe. I have the rear cover off and I am lost from there.

Remove the pinion gear, cross pin bolt
Remove the cross pin
Push axle in & then remove C-Clip,
pull axle out

You need to remove the differential cover. If I remember correctly there should be a bolt or pin that you remove towards the inside of the axle where it enters the carrier. You may have to ratate the differential to see it. After you remove it you push the axle in a little bit and then 2 keepers will drop out and after that the axle should pull right out.

Axle Shaft Bearing & Seal Removal & Installation To Remove:

1. Raise and safely support the vehicle.
2. Remove the axle shaft.
3. If replacing only the seal, remove the seal using a suitable seal removal tool.
4. If replacing the seal and bearing on the 8.6 inch axle, install the slide hammer and adapter behind the bearing and pull out the bearing and seal together.
5. If replacing the rear axle shaft seal and the bearing on the 9.75 inch axle, install the J 29712 or equivalent bearing puller into the axle housing behind the axle bearing.
6. Remove the axle shaft seal and the bearing by tightening the nut on the J 29712 bearing puller.

Use a slide hammer, bearing puller and adapter to remove the old axle bearing

To Install:

1. Install the axle shaft bearing using a suitable size driver. Drive the bearing into the housing until the tool bottoms against the tube.
2. Lubricate the seal lip and install the seal with a suitable seal driver. Make sure the seal is fully seated in the axle tube.
3. Install the axle shaft.
4. Fill the rear axle with the correct lubricant.
5. Lower the vehicle.

First thing is to make sure you chock the front tires so the truck will not roll. Raise the rear end and set it on jack stands. Put the transmission in Neutral and make sure the parking brake is off. Remove the rear tires and disassemble the brakes on the side with the leaking seal. Place a drain pan under the rear differential and remove the cover. Remove the differential shaft lock bolt. You will need to turn the drive shaft by hand to access the bolt. It will be on the right side off the spider gear housing. Only use a 5/16 or 8mm 6 point box end wrench to remove the bolt. After you remove the bolt reach on the top of the spider gear housing and push the differential lock shaft down to remove it. Make sure the spider gears do not rotate after you remove the shaft. If they do you will need to realign everything to reinstall the lock shaft. Push the axle shaft in enough to remove the "C" clip from the tip of it. The axle will now slide out of the rear end. You can use the tip of the axle shaft to remove the axle seal. If you're changing the bearing as well you will need a slide hammer with axle bearing adapters to remove it. You can use a socket and hammer to install the new bearing and seal. Be careful not to damage the bearing and seal. I recommend packing grease in the back side of the seal. This helps prevent the spring on the seal lip from coming off. Assembly is the reverse. Clean off all the gear oil from the differential cover and the axle. You can use RTV as a gasket if the OEM gasket is damaged. Fill the rear end with new gear oil of the proper type. Refer to your owner's manual.

this is very hard if you do not know what you are doing. Ill try to step you through this

• pull wheels
• drain pun-kin case
• pull rear cover
• in between the spider and axle sets pull C ring with needle nose pliers
• pull hub and axle out CAREFULLY as there are roller bearings on the end of the axle housing
• pull seal out at the end of axle housing
• tap in new seal CAREFULLY and straight DO NOT BEND IT or it will be junk
• replace axle carefully as the roller bearings are still there
• replace C clip to original position
• replace axle diff cover and replace the gasket with a new one
• refill diff case
  
• install tire
• your good to go
  

remove the center cover facing the rear of the truck. you will see side gears with the shafts axle end at each side gear. a C clip will have to be removed from each shaft at the end of each axle. Then remove the wheels and pull out the axles

Not that difficult, raise and support the rear of the truck and remove the wheels. Might as well replace both sides so you know you have new seals, remove the differential cover and drain the fluid. Once differential is opened and cleaned , remove the axle "C" clip that hold the axle in place and slide the axle out. Once the axle is out remove the wheel seal and clean around the area. This would be a good time to replace the wheel bearing too since you have access to them and there not that expensive. Install the new bearing and seal, note make sure you oiled the bearing and seal before installing it back and take care when installing the axle back in and "C: clip. Use RTV silicon gasket maker to seal the differential cover and wheels back on and lower. If your lazy like i am, you can drain the differential fluid and replace it with a 50/50 mix with gear oil and Lucas engine oil additives. That may stop the leak and get you a few more miles. You gear oil is 75W-90 and the capacity is 2.6 liters and 3.6 liters if you have the 11.50 Ring gear. Good luck and hope this helps. 

Section 05-02A: Axle, Integral Carrier — 8.8-Inch Ring Gear 1994 Town Car, Crown Victoria/Grand Marquis. Workshop Manual REMOVAL AND INSTALLATION Axle Shaft NOTE: Whenever replacing the rear axle lubricant, use Rear Axle Lubricant XY-90-QL (ESP-M2C154-A) or equivalent.
Removal
CAUTION: The rear brake anti-lock sensor must be removed before the axle shafts are removed. The rear brake anti-lock sensor is bolted on the rear disc brake caliper anchor plate.

1. Raise vehicle to desired working height. Refer to Section 00-02 . Remove rear wheel (1007) and tire assembly. Remove rear disc brake calipers (2552) and rear disc brake rotors (2C026) .
   
   
   
   
   

1. Clean all dirt from area of axle housing cover with a wire brush and/or cloth.

1. Drain rear axle lubricant by removing the axle housing cover .

1. Remove differential pinion shaft lock pin and differential pinion shaft .
   
   
   
   

1. Push flanged end of the axle shafts toward the center of the vehicle and remove the rear axle shaft retaining u-washer from the button end of the axle shaft .
   
   
   
   

1. Remove axle shaft from the rear axle housing , being careful not to damage the inner wheel bearing oil seal (1177) and rear brake anti-lock sensor ring.

Installation
NOTE: Check for presence of rear axle shaft o-ring (4A332) on the spline end of the shaft and install if not present.
CAUTION: Care must be taken not to let axle shaft splines damage oil seal or bearing assembly.

1. Carefully slide axle shaft into rear axle housing without damaging rear wheel bearing (1225) or rear brake anti-lock sensor indicator (2C189) . Start splines into side gear and push firmly until the button end of axle shaft can be seen in the differential case .

1. Install the rear axle shaft retaining u-washer on the button end of the axle shaft splines, then pull the shaft outboard until the shaft splines engage and the rear axle shaft retaining u-washer seats in the counterbore of the differential side gear .

1. Position the differential pinion shaft through the differential case and differential pinion gears , aligning the hole in the differential pinion shaft with the lock bolt hole. Apply Rear Axle Lubricant to differential pinion shaft lock pin . Install differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 lb-ft). CAUTION: Differential pinion shaft lock pin must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA (WSK-M2G349-A1) or equivalent.
   
   
   
   
   NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone rubber or new silicone rubber must be applied.
   CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the cover bolts in a crosswise pattern to ensure uniform draw on axle housing cover .
   

1. Apply Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A or ESE-M4G195-A) or equivalent. Install axle housing cover and tighten retaining bolts to 28-38 Nm (38-52 lb-ft).
   
   
   
   

1. Add Motorcraft Rear Axle Lubricant XY-90-QL or KL (ESP-M2C154-A) or equivalent until it is 6-14mm (1/4-9/16 inch) below bottom of fill hole. Add 118.3 mL (4 oz) of Ford Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent to Traction-Lok axles. Install fill plug and tighten to 20-41 Nm (15-30 lb-ft).

1. Install rear brake anti-lock sensor indicator . Tighten retaining bolt to 4.5-6.8 Nm (40-60 lb-in).

1. Install rear disc brake caliper and rear disc brake rotor .

1. Install wheels and tires.

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1. Insert Rear Bearing Remover T85L-1225-AH in bore and position it behind bearing so tangs on tool engage bearing outer race. Remove rear wheel bearing and inner wheel bearing oil seal as a unit, using Impact Slide Hammer T50T-100-A.
   
   Rear Disc Brake Caliper Anchor Plate
   
   
   
   
   

1. Lubricate the rear wheel bearing with Rear Axle Lubricant.
   
   
   
   

1. Install rear wheel bearing into the housing bore using Axle Tube Bearing Replacer T78P-1225-A.
   
   
   
   CAUTION: Installation of rear wheel bearing or inner wheel bearing oil seal assembly without proper tool may result in an early bearing or seal failure. If inner wheel bearing oil seal becomes cocked in bore during installation, remove it and install a new one.
   

1. Install the inner wheel bearing oil seal using Axle Tube Seal Replacer T78P-1177-A. Use Premium Long-Life Grease XG-1-C or K (ESA-M1C75-B) or equivalent between the lips of the inner wheel bearing oil seal .
   
   
   
   

1. Install axle shafts as outlined.

SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Axle Shaft Removal

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .

1. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.

1. Remove the differential pinion shaft (4211).
   1. Remove the differential pinion shaft lock bolt (4241).
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
   Remove the U-washer (4N237).
   1. Push the axle shafts (4234) inboard.
   1. Remove the U-washer.

1. CAUTION: Damage to the rear brake anti-lock sensor (2C190) may occur if it is not removed before the axle shaft.
   Carefully remove the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .

1. CAUTION: Do not damage the wheel bearing oil seal.
   Remove the axle shaft.

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Rear Wheel Bearing and Axle Shaft Oil Seal Removal

1. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.

1. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged.
   Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.

Installation

1. Lubricate the new rear wheel bearing with the specified lubricant.

1. Using the special tools, install the new rear wheel bearing.

1. Lubricate the lip of the new wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Using the special tools, install the new wheel bearing oil seal.

1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.

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Installation

1. Lubricate the lip of the wheel bearing oil seal
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. CAUTION: Do not damage the wheel bearing oil seal.
   Install the two axle shafts.

1. CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
   Install the U-washer.
   1. Position the two U-washers on the button end of the axle shaft.
   1. Pull the axle shaft outward.

1. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
   Install the differential pinion shaft.
   1. Align the hole in the differential pinion shaft with the case lock bolt hole.
   1. Install a new differential pinion shaft lock bolt.

1. Install the differential housing cover and fill the rear axle with the specified lubrication. For additional information, refer to Differential Housing Cover in this section.

1. Install the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .

1. Install the rear brakes. For additional information, refer to Section 206-04 .

1. Install the tire and wheel assembly. For additional information, refer to Section 204-04 .

1. Lower the vehicle.

Axle Shaft Removal

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the differential housing cover (4033).
   1. Loosen the bolts and drain the lubricant from the rear axle housing (4010).
   1. Remove the bolts.
   1. Remove the differential housing cover.

Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .

1. CAUTION: Turning the differential case (4204) or an axle shaft (4234) with the differential pinion shaft (4211) removed will cause the differential pinion gears (4215) to fall out of the assembly and damage the components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.
2. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
3. Remove the U-washer (4N237).
4. Push the axle shaft inboard.
5. Remove the U-washer.

Reinstall the differential pinion shaft.

1. Install the differential pinion shaft.
2. Install the differential pinion shaft lock bolt finger-tight.
3. CAUTION: Do not damage the wheel bearing oil seal (1177).
   Remove the axle shaft.

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Seal Removal

1. Remove the axle shaft (4334). For additional information, refer to Axle Shaft in this section.

1. CAUTION: Never remove the wheel bearing oil seal (1177) by itself. Always remove the rear wheel bearing (1225) and the inner wheel bearing oil seal at the same time.
   NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material.
   Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.

Installation

1. Lubricate the new rear wheel bearing.
   • For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
   • For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

1. Using the special tools, install the rear wheel bearing.

1. Lubricate the lip of the new wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Using the special tools, install the wheel bearing oil seal.

1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.