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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 879 (Front Drive Axle - 4WD) >> Repair Instructions >> Inner Shaft and/or Housing Replacement - Front Drive Axle (S4WD) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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  .
  2. Install the new clutch fork seal using the J 33799  .
  3. Install the inner axle shaft into the inner axle shaft housing.
    Fig 1: Installing Thrust Washer Into Inner Axle Shaft Housing
    G01467995Courtesy of GENERAL MOTORS CORP.
  4. Install the thrust washer into the inner axle shaft housing. Use chassis grease in order to hold the thrust washer in place.

    Ensure the tabs on the thrust washer align with the slot in the inner axle shaft housing.

  5. Install the new retaining ring into the clutch gear.
  6. Install the clutch gear onto the inner axle shaft. Drive the clutch gear into place with a plastic hammer.
    Fig 2: Installing Different Components Into Inner Axle Shaft Housing
    G01467996Courtesy of GENERAL MOTORS CORP.
  7. Install the following components into the inner axle shaft housing:
    • The thrust washer (9)
    • The clutch fork inner spring (16)
    • The clutch fork (17)
    • The clutch fork sleeve (11)
    • The clutch cable retainer spring (15)
  8. Apply sealant (GM P/N 1052492 or equivalent) to the inner axle housing to differential carrier sealing surface.
  9. Install the inner axle shaft housing to the differential carrier assembly.
  10. Install the inner axle shaft housing bolt at the 1 o'clock position.

    Tighten the bolt finger tight.

    Fig 3: Installing Inner Axle Shaft Housing To Frame Bracket Bolts
    G01467997Courtesy of GENERAL MOTORS CORP.
  11. Pull the inner axle shaft housing down in order to install the bolt at the 11 o'clock position.

    Tighten the bolt finger tight.

  12. Install the clutch cable housing and the clutch cable. Refer to CLUTCH CABLE REPLACEMENT - FRONT DRIVE AXLE  .
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  13. Install the inner axle shaft housing to the frame bracket bolts, washers, and the nuts.

    Tighten 

    • Tighten the inner axle shaft housing frame bracket nuts to 98 N.m (72 lb ft).
    • Tighten the inner axle shaft housing to differential carrier assembly bolts to 48 N.m (36 lb ft).
  14. Install the right side wheel drive shaft.
  15. Inspect the axle lubricant level and add, if necessary. Refer to LUBRICANT LEVEL INSPECTION - FRONT DRIVE AXLE  .
  16. Lower the vehicle.
    Fig 4: Removing Bolts, Nuts, And Washers From Inner Axle Shaft Housing
    G01467998Courtesy of GENERAL MOTORS CORP.
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