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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1013 (Front Drive Axle) >> Repair Instructions >> Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 S4WD and 9.25 Axles) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the new inner axle shaft bearing and the seal to the axle housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .
  2. Install the inner axle shaft (2) into the inner axle shaft housing (1).

    Carefully tap the inner axle shaft into place with a soft-faced mallet.

    3. Fig 1: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615683Courtesy of GENERAL MOTORS CORP.
  3. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
  4. For the 8.25 inch axle, install the following components into the inner axle shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. The thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    2. The retainer ring (7) into the clutch gear (6).
    3. The clutch gear (6) onto the inner axle shaft (1).

      Drive the clutch gear into place with a plastic hammer.

    4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. The clutch gear shim (9)
    6. The clutch sleeve (8)
    7. The clutch fork assembly (11)
    8. The clutch fork inner spring (10)
    5. Fig 2: Inner Axle Shaft Housing (8.25 Inch)
    GM892810Courtesy of GENERAL MOTORS CORP.
  5. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
      IMPORTANT: Use chassis grease in order to hold the thrust washer in place.
    1. The thrust washer (5)

      Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    2. The second thrust washer (6)
    3. The retainer ring (7) onto the inner axle shaft (1).
    4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5. The clutch gear shim (9)
    6. The clutch sleeve (8)
    7. The clutch fork assembly (11)
    8. The clutch fork inner spring (10)
    6. Fig 3: Inner Axle Shaft Housing (9.25 Inch)
    GM892812Courtesy of GENERAL MOTORS CORP.
  6. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
  7. Install the inner axle shaft housing assembly to the differential carrier assembly.
    8. Fig 4: Installing Inner Axle Shaft Housing Assembly - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM893259Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the inner axle shaft housing bolts.

    Tighten:  Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).

    9. Fig 5: Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834261Courtesy of GENERAL MOTORS CORP.
  9. For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
    1. Slide the front axle mounting bracket towards the frame.

      Install the front axle mounting bracket studs into the inner shaft housing mounting flange.

      It may be necessary to push up on the front axle mounting bracket and/or pull down on the inner axle housing in order to gain enough clearance to install the mounting bracket studs into the inner shaft housing.

    2. Install the front axle mounting bracket to frame nuts.

      Tighten:  Tighten the inner axle shaft housing mounting bracket to frame nuts to 90 N.m (67 lb ft).

    10. Fig 6: Installing Front Axle Mounting Bracket & Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM365933Courtesy of GENERAL MOTORS CORP.
  10. Install the inner axle shaft housing washers and nuts to the bracket.

    Tighten:  Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft).

    11. Fig 7: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  11. Connect the wheel drive shaft inboard flange to the inner axle shaft.
  12. Install the wheel drive shaft inboard flange to the inner axle shaft bolts.

    Tighten:  Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).

    13. Fig 8: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle
    GM763646Courtesy of GENERAL MOTORS CORP.
  13. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  14. Connect the wire harness to the inner axle shaft housing.
    15. Fig 9: Connecting Wire Harness To Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834265Courtesy of GENERAL MOTORS CORP.
  15. Connect the electrical connector to the front axle actuator.
    16. Fig 10: Connecting Front Axle Actuator Electrical Connector - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834234Courtesy of GENERAL MOTORS CORP.
  16. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
  17. Lower the vehicle.
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