Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Install the new inner axle shaft bearing and the seal to the axle housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement
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.

Fig 1: Inner Axle Shaft
Courtesy of GENERAL MOTORS CORP.
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. 3.1. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
2. 3.2. The retainer ring (7) into the clutch gear (6).
3. 3.3 The clutch gear (6) onto the inner axle shaft (1).
  Drive the clutch gear into place with a plastic hammer.
  
  Fig 2: Inner Axle Shaft Housing & Components (8.25 Inch Axle)
  Courtesy of GENERAL MOTORS CORP.
4. 3.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
5. 3.5. The clutch gear shim (9)
6. 3.6. The clutch sleeve (8)
7. 3.7. The clutch fork assembly (11)
8. 3.8. The clutch fork inner spring (10) into the differential carrier case.
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. 4.1. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
2. 4.2. The second thrust washer (6)
3. 4.3. The retainer ring (7) onto the inner axle shaft (1).
4. 4.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
5. 4.5. The clutch gear shim (9)
6. 4.6. The clutch sleeve (8)
7. 4.7. The clutch fork assembly (11)
8. 4.8. The clutch fork inner spring (10) into the differential carrier case.
Fig 3: Inner Axle Shaft Housing & Components (9.25 Inch Axle)
Courtesy of GENERAL MOTORS CORP.
Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
Install the inner axle shaft housing assembly to the differential carrier assembly.

Fig 4: Install Inner Axle Shaft Housing Assembly
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE .
Install the inner axle shaft housing bolts.
Tighten

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

Fig 5: Inner Axle Shaft Housing Bolts
Courtesy of GENERAL MOTORS CORP.
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).
Connect the wheel drive shaft inboard flange to the inner axle shaft.

Fig 6: Inner Axle Shaft Housing Washers & Nuts
Courtesy of GENERAL MOTORS CORP.
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).
Install the stabilizer shaft link assembly. Refer to STABILIZER SHAFT LINK REPLACEMENT .

Fig 7: Wheel Drive Shaft Inboard Flange Bolts
Courtesy of GENERAL MOTORS CORP.
Connect the wire harness to the inner axle shaft housing.

Fig 8: Connect Wire Harness To Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
Connect the electrical connector to the front axle actuator.
Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Replacement - Front Drive Axle .
Lower the vehicle.

Fig 9: Connect Front Axle Actuator Electrical Connector

Courtesy of GENERAL MOTORS CORP.