Inner Shaft and/or Housing Replacement - Front Drive Axle (S4WD)
Inner Shaft and/or Housing Replacement - Front Drive Axle (S4WD)Tools Required
^ J33799 Clutch Fork Housing Seal Installer
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the right side wheel drive shaft.
3. Disconnect the clutch cable from the clutch fork.
4. Remove the bolts, the nuts, and the washers from the inner axle shaft housing.
5. Remove the remaining 2 inner axle shaft housing to differential carrier assembly bolts.
Important: Do not allow the following components to fall out of the differential carrier assembly or become damaged:
^ The thrust washers
^ The clutch fork sleeve
^ The clutch fork inner axle shaft
6. Remove the inner axle shaft and housing assembly by working the shaft and housing around the drive axle.
7. Remove the following components from the inner axle shaft housing:
7.1. The clutch cable retainer spring
7.2. The clutch fork assembly
7.3. The clutch fork inner spring
7.4. The clutch fork sleeve
7.5. The thrust washer
7.6. The clutch gear by doing the following:
7.6.1. Clamp the inner shaft housing in a vise. Clamp only on the mounting flange.
7.6.2. Strike the inside surface of the axle shaft with a hammer and a brass drift in order to dislodge the clutch gear from the inner axle shaft.
7.6.3. Remove the clutch gear.
8. Remove the thrust washer.
9. Remove the inner axle shaft.
10. Remove the clutch fork seal. Use a punch to drive out the seal.
11. Remove the inner axle seal and the bearing from the inner axle shaft housing.
Installation Procedure
1. Install the new inner axle shaft bearing and the seal to the axle housing.
2. Install the new clutch fork seal using the J33799.
3. Install the inner axle shaft into the inner axle shaft housing.
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.
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.
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.
Notice: Refer to Fastener Notice in Service Precautions.
13. Install the inner axle shaft housing to the frame bracket bolts, washers, and the nuts.
^ Tighten the inner axle shaft housing frame bracket nuts to 98 Nm (72 ft. lbs.).
^ Tighten the inner axle shaft housing to differential carrier assembly bolts to 48 Nm (36 ft. lbs.).
14. Install the right side wheel drive shaft.
15. Inspect the axle lubricant level and add, if necessary.
16. Lower the vehicle.