Removal Procedure

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 GMC Sierra, 2002 Chevrolet Tahoe, and 2002 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.

Raise the vehicle. Refer to LIFTING & JACKING THE VEHICLE .
Drain the differential carrier assembly. Refer to LUBRICANT REPLACEMENT - FRONT DRIVE AXLE .
Disconnect the electrical connector from the electric motor actuator.

Fig 1: Disconnecting Electrical Connector From Electric Motor Actuator
Courtesy of GENERAL MOTORS CORP.
Disconnect the wire harness from the inner axle shaft housing.

Fig 2: Disconnecting Wire Harness From Inner Axle Shaft Housing

Courtesy of GENERAL MOTORS CORP.

Remove the stabilizer shaft link assembly. Refer to STABILIZER SHAFT LINK REPLACEMENT .
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: Removing Wheel Drive Shaft Inboard Flange Bolts From Inner Axle Shaft
Courtesy of GENERAL MOTORS CORP.
Remove the inner axle shaft housing nuts from the bracket.

Fig 4: Removing Inner Axle Shaft Housing Nuts From Bracket
Courtesy of GENERAL MOTORS CORP.
For 25 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)
Remove the inner axle shaft housing bolts from the differential carrier case.

Fig 6: Removing Inner Axle Shaft Housing Bolts From Differential Carrier Case
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 From Differential Carrier Assembly
Courtesy of GENERAL MOTORS CORP.
For the 8.25 inch axle - 1st design, remove the following components from the inner axle shaft housing:
1. The clutch fork inner spring (10)
2. The clutch fork assembly components (14, 13, 12, 11)
3. The clutch shaft shim (9)
4. Remove the clutch sleeve (8)
5. Remove 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. Remove the thrust washer (5)
Fig 8: Inner Axle Shaft Housing Components
For the 8.25 inch axle - 2nd design, 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 9: Removing Components Of Inner Axle Shaft Housing
Courtesy of GENERAL MOTORS CORP.
For the 9.25 inch axle - 1st design, remove the following components from the inner axle shaft housing:
1. The clutch fork inner spring (10)
2. The clutch fork assembly components (14, 13, 12, 11)
3. The clutch shaft shim (9)
4. The clutch sleeve (8)
5. The retainer ring (7)
6. The thrust washers (5, 6)
Fig 10: Inner Axle Shaft Housing Components
For the 9.25 inch axle - 2nd design, 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 11: Removing Components Of Inner Axle Shaft Housing
  Courtesy of GENERAL MOTORS CORP.
Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet.

Fig 12: Removing Inner Axle Shaft
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 .