Tools Required

• J 8092  Universal Driver Handle - 3/4 in - 10
• J 36609  Axle Tube Bearing Installer
• J 36600  Output Shaft Seal Installer (8.25 inch axle)
• J 22833  Housing Drive Seal Installer (9.25 inch axle)
• J 34672  Depth Gage
• J 8001  Dial Indicator Set

The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced:

• The inner axle shaft
• The inner axle shaft housing
• The output shaft
• The differential carrier case
• The ring and pinion gears
• The differential case assembly
• The bearings
• The carrier connector

Front drive axle clutch shims are available in the following sizes:

Fig 1: Front Drive Axle Clutch Shim Specifications

Courtesy of GENERAL MOTORS CORP.

1. Install the inner axle shaft bearing with the square shoulder in using the J 8092  (1) and the J 36609  (2).
   Fig 2: Install Inner Axle Shaft Bearing With Square Shoulder Using J 8092 & J 36609

   Courtesy of GENERAL MOTORS CORP.
2. Install the new inner axle shaft seal using the J 36600,  8.25 inch axle, or the J 22833,  9.25 inch axle.
   Fig 3: Install New Inner Axle Shaft Seal

   Courtesy of GENERAL MOTORS CORP.
3. Install the following components into the inner axle shaft housing, 8.25 inch axle:
   1. 3.1. Install the inner axle shaft (1) into the front drive axle housing (4).
   2. 3.2. Install the thrust washer (5)
   3. 3.3. Install the retaining ring (7) into the front drive axle clutch gear (6).
   4. 3.4. Install the front drive axle clutch gear (6) onto the inner axle shaft (1).

      Drive the front drive axle clutch gear (6) into place with a plastic hammer.

   Fig 4: Install Inner Axle Shaft Housing & Components (8.25 Inch)

   Courtesy of GENERAL MOTORS CORP.
4. Install the following components into the inner axle shaft housing, 9.25 inch axle:
   1. 4.1. Install the inner axle shaft (1) into the front drive axle housing (4).
   2. 4.2. Install the thrust washers (5, 6).
   3. 4.3. Install the retaining ring (7) into the inner axle shaft (1).
   Fig 5: Install Inner Axle Shaft Housing & Components (9.25 Inch)

   Courtesy of GENERAL MOTORS CORP.
   IMPORTANT: In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.
5. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.
6. Using the J 34672,  measure the distance from the edge of the front drive axle clutch gear to the machined flange surface of the inner axle housing.
   Fig 6: Measuring Distance From Front Drive Axle Clutch Gear To Inner Axle Housing Surface

   Courtesy of GENERAL MOTORS CORP.
7. Using the J 34672,  measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7.
9. The correct shim size will be one size smaller than the figure obtained in the previous step.

   Note the following examples:

   • If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim.
   • If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.
   Fig 7: Measuring Distance From Differential Carrier Housing To Front Drive Axle Clutch Shaft

   Courtesy of GENERAL MOTORS CORP.