Installation Procedure

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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 .
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: Installing Inner Axle Shaft Into Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
For the 8.25 inch axle 1st design, 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 (14, 13, 12, 11)
8. The clutch fork inner spring (10) into the differential carrier case.
Fig 2: Inner Axle Shaft Housing Components
For the 8.25 inch axle 2nd design, 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) into the differential carrier case.
Fig 3: Installing Components Into Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
For the 9.25 inch axle 1st design, 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 (14, 13 ,12, 11)
8. The clutch fork inner spring (10) into the differential carrier case.
Fig 4: Inner Axle Shaft Housing Components
For the 9.25 inch axle 2nd design, install the following components into the inner axle shaft housing:
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) into the differential carrier case.
Fig 5: Installing Components Into Inner Axle Shaft Housing
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 6: Installing Inner Axle Shaft Housing Assembly To Differential Carrier 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 7: Installing Inner Axle Shaft Housing Bolts
Courtesy of GENERAL MOTORS CORP.
For 25 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle housing:
1. Slide the front axle mounting bracket towards the frame.
2. 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 brackets studs into the inner shaft housing.
3. Install the front axle mounting bracket to frame nuts.
  Tighten
  
  Tighten the front axle mounting bracket to frame nuts to 90 Nm (67 lb ft).
Fig 8: Front Axle Mounting Bracket -- Front Drive Axle (8.25 S4WD and 9.25 Axles)
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).

Fig 9: Inner Axle Shaft Housing Washers And Nuts To Bracket
Courtesy of GENERAL MOTORS CORP.
Connect the wheel drive shaft inboard flange to the inner axle shaft.
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).

Fig 10: Installing Wheel Drive Shaft Inboard Flange To Inner Axle Shaft Bolts
Courtesy of GENERAL MOTORS CORP.
Install the stabilizer shaft link assembly. Refer to STABILIZER SHAFT LINK REPLACEMENT .
Connect the wire harness to the inner axle shaft housing.

Fig 11: Connecting Wire Harness To Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
Connect the electrical connector to the front axle actuator.

Fig 12: Connecting Electrical Connector To Front Axle Actuator
Courtesy of GENERAL MOTORS CORP.
Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to LUBRICANT REPLACEMENT - FRONT DRIVE AXLE .
Lower the vehicle.