Output Shaft: Service and Repair

Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement

Tools Required
* J 8092 Universal Driver Handle 3/4 Inch - 10
* J 2619-01 Slide Hammer
* J 29369-1 Bearing Remover
* J 45233 Differential Bearing Adjuster Needle Bearing Replacer - RH

Removal Procedure

Important: When servicing the inner drive shaft housing, the inner drive shaft bearing must be replaced. The bearing IS NOT serviced with the inner drive shaft housing .





1. Remove the left differential carrier mounting bracket. Refer to Differential Carrier Assembly Bushing and Bracket Replacement (Service and Repair) .




2. Remove the retaining bolts from the disconnect housing.




3. Remove the disconnect housing.




4. Remove the clutch shift fork and spring.
5. Remove the thrust washer, clutch gear, clutch sleeve and gasket.




6. Remove the inner drive shaft and thrust washer.




7. Remove the retaining bolts from the housing assembly, if needed.




8. Remove the axle shaft housing assembly from the deferential housing, if needed.




9. Remove the housing gasket
10. Install the intermediate shaft housing in a suitable clamping devise.




11. Using the J 29369-1 (1) and the J 2619-01 (2), remove the inner drive shaft bearing.

Installation Procedure




1. Using the J 45233 (1) and the J 8092 (2), install the inner drive shaft bearing.
2. Apply a small amount of grease to the housing gasket to hold it in place.
3. Install the intermediate shaft housing.





Notice: Refer to Fastener Notice (Fastener Notice) .

Important: Perform the following:


* Clean the thread locking material from the bolts.

* Apply new thread locking material to the bolts (DRI-LOC 204 Red, GM P/N 12345493.


4. Install the retaining bolts.

Tighten the retaining bolts to 68 N.m (50 lb ft).




5. Install the inner drive shaft and thrust washer.




6. Install the thrust washer, clutch gear, clutch sleeve.
7. Install the shift fork and spring.
8. Install the disconnect housing gasket.




9. Install the retaining bolts.

Tighten the retaining bolts to 60 N.m (44 lb ft).




10. Install the differential mounting bracket. Refer to Differential Carrier Assembly Bushing and Bracket Replacement (Service and Repair) .
11. Lower the vehicle.