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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1388 (Front Drive Axle) >> Repair Instructions >> Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Axle Shaft Inner Flange - Front Drive Axle
    GM1581721Courtesy of GENERAL MOTORS CORP.
    NOTE: If only the left side inner axle shaft was removed, install the shaft by performing the following.
  1. Using a soft-faced mallet, carefully tap the inner axle shaft until it is fully seated in the differential case side gear.
  2. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
  3. Connect the wheel drive shaft to the inner axle shaft.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the wheel drive shaft inboard flange to inner axle shaft bolts and tighten to 79 N.m (58 lb ft).
    5. NOTE: If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing following the steps.
  5. Install the new inner axle shaft bearing and the seal to the axle housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .
    6. Fig 2: Identifying Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM615683Courtesy of GENERAL MOTORS CORP.
  6. Using a soft faced mallet, carefully tap the inner axle shaft (2) into the inner axle shaft housing (1).
  7. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
    8. Fig 3: View Of Inner Axle Shaft & Components
    GM1690931Courtesy of GENERAL MOTORS CORP.
  8. For the 8.25 inch axle, install the following components into the inner axle housing:
    1. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
      2. NOTE: Use chassis grease in order to hold the thrust washer in place.
    2. Axle shaft tabbed thrust washer (6)
    3. Axle shaft thrust washer (7)
    4. Axle shaft snap ring (8)
    5. Shifter connector gear (9)
    6. Shifter fork (11)
    7. Shifter fork rod (10)
    8. Shifter fork spring (12)
    9. Inner Axle shaft housing gasket (5)
    9. Fig 4: Identifying Inner Axle Shaft Housing Components
    GM2047154Courtesy of GENERAL MOTORS CORP.
  9. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
      NOTE: Use chassis grease in order to hold the thrust washer in place.
    1. Thrust washer (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    2. Retainer ring (6) onto the inner axle shaft (1)
    3. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    4. Clutch gear shim (8)
    5. Clutch sleeve (7)
    6. Clutch fork assembly (10)
    7. Clutch fork inner spring (9)
    10. NOTE: The following service procedure is for the 9.25 inch axle ONLY. If servicing the 8.25 inch axle, proceed to step 12. The 8.25 inch axle uses a gasket.
  10. If servicing the 9.25 inch axle, apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  11. If servicing the 8.25 inch axle, install the axle housing gasket on to the differential carrier.
    12. Fig 5: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly
    GM893259Courtesy of GENERAL MOTORS CORP.
  12. Install the inner axle shaft housing assembly to the differential carrier assembly.
    13. Fig 6: Identifying Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)
    GM834261Courtesy of GENERAL MOTORS CORP.
    NOTE: If servicing the 9.25 inch axle, proceed to step 15.
  13. If servicing the 8.25 inch axle, install the inner axle shaft housing bolts and tighten to 55 N.m (41 lb ft).
  14. If servicing the 9.25 inch axle, install the inner axle shaft housing bolts and tighten to 40 N.m (30 lb ft).
    15. Fig 7: View Of Front Axle Mounting Bracket (25/35 Series)
    GM365933Courtesy of GENERAL MOTORS CORP.
    NOTE: For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing.
  15. Slide the front axle mounting bracket towards the frame.
  16. Install the front axle mounting bracket studs into the inner shaft housing mounting flange.
  17. It may be necessary to push up on the front axle mounting bracket and/or pull down on the inner axle housing in order to gain enough clearance to install the mounting bracket studs into the inner shaft housing.
  18. Install the front axle mounting bracket to frame nuts and tighten to 90 N.m (67 lb ft).
    19. Fig 8: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  19. Install the inner axle shaft housing washers and nuts to the bracket and tighten the nuts to 100 N.m (75 lb ft).
  20. Connect the wheel drive shaft inboard flange to the inner axle shaft.
    21. Fig 9: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle
    GM763646Courtesy of GENERAL MOTORS CORP.
  21. Install the wheel drive shaft inboard flange to the inner axle shaft bolts and tighten the bolts to 79 N.m (58 lb ft).
    22. Fig 10: View Of Inner Axle Shaft Housing Wire Harness
    GM834265Courtesy of GENERAL MOTORS CORP.
  22. Connect the wire harness to the inner axle shaft housing.
    23. Fig 11: View Of Front Axle Actuator Electrical Connector
    GM834234Courtesy of GENERAL MOTORS CORP.
  23. Connect the electrical connector to actuator.
  24. For vehicles equipped with the 9.25 inch axle, install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (2500, 3500) or Stabilizer Shaft Link Replacement (1500) .
  25. For vehicles equipped with the 8.25 inch axle, install the front shock module. Refer to Shock Absorber and Spring Assembly Replacement .
  26. With either replacement procedure, fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Front Axle Lubricant Replacement .
  27. Lower the vehicle.
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