Removal 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.

Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
Disconnect the electrical connector from the electric motor actuator.

Fig 1: Disconnecting Electric Motor Actuator Electrical Connector - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM834234

Courtesy of GENERAL MOTORS CORP.

Disconnect the wire harness from the inner axle shaft housing.

Fig 2: Inner Axle Shaft Housing Wire Harness - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM834265

Courtesy of GENERAL MOTORS CORP.

Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
Disconnect the wheel drive shaft from the inner axle shaft.

Fig 3: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle

GM763646

Courtesy of GENERAL MOTORS CORP.

Remove the inner axle shaft housing nuts from the bracket.

Fig 4: View Of Inner Axle Housing Nuts

GM834241

Courtesy of GENERAL MOTORS CORP.

For 25/35 series vehicles, perform the following steps in order to provide additional clearance so the inner axle housing can be removed from the vehicle:
1. Remove the front axle mounting bracket to frame nuts.
2. Slide the front axle mounting bracket towards the engine. It may be necessary to pull down on the inner axle housing and/or push up on the mounting bracket in order to gain clearance.

Fig 5: Removing Front Axle Mounting Bracket - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM365933

Courtesy of GENERAL MOTORS CORP.

Remove the inner axle shaft housing bolts from the differential carrier case.

Fig 6: Removing Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM834261

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Keep the open end of the inner axle shaft housing up.

Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.

Fig 7: Removing Inner Axle Shaft Housing Assembly - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM615922

Courtesy of GENERAL MOTORS CORP.

For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
1. The clutch fork inner spring (10)
2. The clutch fork assembly (11)
3. The clutch shaft shim (9)
4. The clutch sleeve (8)
5. The clutch gear (6) by doing the following:
  1. Clamp the inner axle shaft housing (4) in a vise.
    Clamp only on the mounting flange.
  2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
6. The thrust washer (5)

Fig 8: Inner Axle Shaft Housing Components (8.25 Inch)

GM892810

Courtesy of GENERAL MOTORS CORP.

For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
1. The clutch fork inner spring (10)
2. The clutch fork assembly (11)
3. The clutch shaft shim (9)
4. The clutch sleeve (8)
5. The retainer ring (7)
6. The thrust washers (5, 6)

Fig 9: Inner Axle Shaft Housing Components (9.25 Inch)

GM892812

Courtesy of GENERAL MOTORS CORP.

Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.

Fig 10: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)

GM615683

Courtesy of GENERAL MOTORS CORP.

Remove the inner axle seal and the bearing from the axle housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .