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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 987 (Front Drive Axle) >> Repair Instructions >> Inner Shaft and/or Housing Replacement - Front Drive Axle (8.25 F4WD Axle) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. 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 new seal to the inner axle shaft housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .
  2. Install the inner axle shaft into the inner axle shaft housing.

    Do not install the inner axle shaft completely into the inner axle shaft housing at this time.

  3. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
  4. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the inner axle shaft housing bolts.

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

    6. Fig 1: Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 F4WD Axle)
    GM763644Courtesy of GENERAL MOTORS CORP.
  6. Install the inner axle shaft housing nuts to the bracket.

    Tighten:  Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft).

    7. Fig 2: Inner Axle Shaft Housing Nuts - Front Drive Axle (8.25 F4WD Axle)
    GM763653Courtesy of GENERAL MOTORS CORP.
  7. Install the inner axle shaft into the differential case side gear by doing the following:
    1. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    2. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear.
    3. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
  8. Install the wheel drive shaft inboard flange to the inner axle shaft.
  9. Install the wheel drive shaft inboard flange to inner axle shaft bolts.

    Tighten:  Tighten the wheel drive shaft inboard flange to inner axle shaft bolts to 79 N.m (58 lb ft).

    10. Fig 3: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle
    GM763646Courtesy of GENERAL MOTORS CORP.
  10. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  11. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
  12. Lower the vehicle.
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