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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1061 (Front Drive Axle) >> Repair Instructions >> Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Drain the differential carrier. Refer to Front Axle Lubricant Replacement .
    3. Fig 1: View Of Front Axle Actuator Electrical Connector
    GM834234Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the actuator electrical connector.
  4. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 17.
    5. Fig 2: Inner Axle Shaft Housing Wire Harness - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834265Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the wire harness from the inner axle housing.
  6. For vehicles equipped with the 8.25 inch axle, remove the front shock module. Refer to Shock Absorber and Spring Assembly Replacement .
    7. Fig 3: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle
    GM763646Courtesy of GENERAL MOTORS CORP.
  7. Remove the wheel drive shaft flange bolts.
    8. IMPORTANT: Support the wheel drive shaft in order to not over flex the constant velocity (CV) joint.
  8. Disconnect the wheel drive shaft from the inner axle shaft.
    9. Fig 4: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  9. Remove the inner axle housing mounting nuts.
    10. Fig 5: Front Axle Mounting Bracket - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM365933Courtesy of GENERAL MOTORS CORP.
  10. For the 25/35 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 shaft and/or push up on the mounting bracket in order to gain clearance.
    11. Fig 6: View Of Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834261Courtesy of GENERAL MOTORS CORP.
  11. Remove the inner axle shaft mounting bolts.
    12. Fig 7: View Of Inner Axle Shaft Housing Assembly - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615922Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Keep the open end of the inner axle housing assembly up.
  12. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
    13. Fig 8: View Of Inner Axle Shaft & Components
    GM1690931Courtesy of GENERAL MOTORS CORP.
  13. For the 8.25 inch axle, remove the following components from the inner axle housing:
    1. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
    2. The shifter fork spring (12)
    3. The shifter fork (11)
    4. The shifter fork rod (10)
    5. The shifter connector gear (9)
    6. The axle shaft snap ring (8)
    7. Axle shaft thrust washer (7)
    8. Axle shaft tabbed thrust washer (6)
    9. Inner axle shaft housing gasket (5)
    14. Fig 9: Inner Axle Shaft Housing Components (9.25 Inch)
    GM892812Courtesy of GENERAL MOTORS CORP.
  14. For the 9.25 inch axle, 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)
    15. Fig 10: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615683Courtesy of GENERAL MOTORS CORP.
  15. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
  16. 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 .
    17. Fig 11: Identifying Inner Axle Shaft - Front Drive Axle
    GM1581720Courtesy of GENERAL MOTORS CORP.
  17. If only replacing the left side inner axle shaft, perform the following steps:
    1. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    2. Disconnect the wheel drive shaft from the inner axle shaft.
    3. Remove the inner axle shaft using a hammer and a brass drift.
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