Removal 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.

Raise the vehicle. Refer to JACKING AND LIFTING .
Drain the differential carrier assembly. Refer to Lubricant Replacement - Front Drive Axle .
Disconnect the electrical connector from the electric motor actuator.

Fig 1: Disconnect Electrical Connector From Electric Motor Actuator
Courtesy of GENERAL MOTORS CORP.
Disconnect the wire harness from the inner axle shaft housing.
Remove the stabilizer shaft link assembly. Refer to STABILIZER SHAFT LINK REPLACEMENT .

Fig 2: Disconnect Wire Harness
Courtesy of GENERAL MOTORS CORP.
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: Wheel Drive Shaft Inboard Flange Bolts
Courtesy of GENERAL MOTORS CORP.
Remove the inner axle shaft housing nuts from the bracket.

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

Fig 5: Inner Axle Shaft Housing Bolts
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 6: Remove Inner Axle Shaft Housing Assembly
Courtesy of GENERAL MOTORS CORP.
For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
1. 10.1. The clutch fork inner spring (10)
2. 10.2. The clutch fork assembly (11)
3. 10.3. The clutch shaft shim (9)
4. 10.4. The clutch sleeve (8)
5. 10.5. The clutch gear (6) by doing the following:
  1. 10.5.1. Clamp the inner axle shaft housing (4) in a vise.
    Clamp only on the mounting flange.
  2. 10.5.2. 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. 10.6. The thrust washer (5)
Fig 7: Inner Axle Shaft Housing & Components (8.25 Inch Axle)
Courtesy of GENERAL MOTORS CORP.
For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
1. 11.1. The clutch fork inner spring (10)
2. 11.2. The clutch fork assembly (11)
3. 11.3. The clutch shaft shim (9)
4. 11.4. The clutch sleeve (8)
5. 11.5. The retainer ring (7)
6. 11.6. The thrust washers (5, 6)
Fig 8: Inner Axle Shaft Housing & Components (9.25 Inch Axle)
Courtesy of GENERAL MOTORS CORP.
Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet.
Remove the inner axle seal and the bearing from the axle housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .

Fig 9: Inner Axle Shaft
Courtesy of GENERAL MOTORS CORP.