Installation Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Axle Shaft Inner Flange - Front Drive Axle

Courtesy of GENERAL MOTORS CORP.

If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
1. 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. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
2. Connect the wheel drive shaft to the inner axle shaft.
3. 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).
If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing following the steps below.
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 .

Fig 2: Axle Shaft & Inner Axle Shaft Housing - Front Drive Axle (8.25 S4WD and 9.25 Axles)

Courtesy of GENERAL MOTORS CORP.

Install the inner axle shaft (2) into the inner axle shaft housing (1).
Carefully tap the inner axle shaft into place with a soft-faced mallet.
Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.

Fig 3: View Of Inner Axle Shaft & Components

Courtesy of GENERAL MOTORS CORP.

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. Axle shaft tabbed thrust washer (6)
3. Axle shaft thrust washer (7)
4. The axle shaft snap ring (8)
5. The shifter connector gear (9)
6. The shifter fork (11)
7. The shifter fork rod (10)
8. The shifter fork spring (12)
9. Inner axle shaft housing gasket (5)

Fig 4: Inner Axle Shaft Housing Components (9.25 Inch)

Courtesy of GENERAL MOTORS CORP.

For the 9.25 inch axle, install the following components into the inner axle shaft housing:
1. The thrust washer (5)-Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
2. The second thrust washer (6)
3. The retainer ring (7) onto the inner axle shaft (1)
4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
5. The clutch gear shim (9)
6. The clutch sleeve (8)
7. The clutch fork assembly (11)
8. The clutch fork inner spring (10)

IMPORTANT: The following service procedure is for the 9.25 inch axle ONLY. The 8.25 inch axle uses a gasket.

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 Sealers, Adhesives, and Lubricants .
If servicing the 8.25 inch axle, install the axle housing gasket on to the differential carrier.

Fig 5: View Of Inner Axle Shaft Housing Assembly To Differential Carrier Assembly

Courtesy of GENERAL MOTORS CORP.

Install the inner axle shaft housing assembly to the differential carrier assembly.

Fig 6: View Of Inner Axle Shaft Housing Bolts - Front Drive Axle (8.25 S4WD and 9.25 Axles)

Courtesy of GENERAL MOTORS CORP.

If servicing the 8.25 inch axle, install the inner axle shaft housing bolts.
Tighten: Tighten the inner axle shaft housing bolts to 55 N.m (41 lb in).
If servicing the 9.25 inch axle, install the inner axle shaft housing bolts.
Tighten: Tighten the inner axle shaft housing bolts to 40 N.m (30 lb in).

Fig 7: View Of Front Axle Mounting Bracket (25/35 Series)

Courtesy of GENERAL MOTORS CORP.

For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
1. Slide the front axle mounting bracket towards the frame.
  Install the front axle mounting bracket studs into the inner shaft housing mounting flange.
  
  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.
2. Install the front axle mounting bracket to frame nuts.
  Tighten: Tighten the inner axle shaft housing mounting bracket to frame nuts to 90 N.m (67 lb ft).

Fig 8: View Of Inner Axle Housing Nuts

Courtesy of GENERAL MOTORS CORP.

Install the inner axle shaft housing washers and nuts to the bracket.
Tighten: Tighten the inner axle shaft housing nuts to 100 N.m (75 lb ft).
Connect the wheel drive shaft inboard flange to the inner axle shaft.

Fig 9: View Of Wheel Drive Shaft Inboard Flange Bolt - Front Drive Axle

Courtesy of GENERAL MOTORS CORP.

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

Fig 10: View Of Inner Axle Shaft Housing Wire Harness - Front Drive Axle (8.25 S4WD and 9.25 Axles)

Courtesy of GENERAL MOTORS CORP.

Connect the wire harness to the inner axle shaft housing.

Fig 11: View Of Front Axle Actuator Electrical Connector

Courtesy of GENERAL MOTORS CORP.

Connect the electrical connector to actuator.
For vehicles equipped with the 9.25 inch axle, remove the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (1500 Series) or Stabilizer Shaft Link Replacement (2500 Series) .
For vehicles equipped with the 8.25 inch axle, remove the front shock module. Refer to Shock Module Replacement .
With either replacement procedure, fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
Lower the vehicle.