Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)

Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (9.25 Inch HD Axle)

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Drain the differential carrier. Refer to Front Axle Lubricant Replacement (8.6/9.25 Inch Axles) Front Axle Lubricant Replacement (8.6/9.25 Inch Axles).

3. Remove the front drive axle actuator. Refer to Front Drive Axle Actuator Replacement Service and Repair.

4. Disconnect the wire harness from the front drive axle inner shaft housing.

Note: Support the wheel drive shaft in order to not over flex the constant velocity (CV) joint.

5. Separate the wheel drive shaft from the front wheel inner drive shaft. Refer to Wheel Drive Shaft Replacement (1500) Wheel Drive Shaft ReplacementWheel Drive Shaft Replacement (2500/3500) Wheel Drive Shaft Replacement.

6. Remove the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (2500, 3500) Front SuspensionStabilizer Shaft Link Replacement (1500) Front Suspension.




7. Remove the two front differential carrier bracket nuts (1).





Note:

* Allow the front drive axle inner shaft housing to drain before completely removing it from the vehicle.

* Keep the open end of the inner axle housing assembly up

8. Remove the six front drive axle inner shaft housing bolts (1).

9. Remove the front drive axle inner shaft housing (2) and the gasket (3).




10. Remove the front drive axle clutch fork inner spring (9) and the clutch fork (10).

11. Remove the front drive axle clutch gear shim (8), sleeve (7), and thrust washer (5).

12. Remove and discard the front drive axle inner shaft retaining ring (6).

13. Remove the front drive axle inner shaft (1).

14. If any of the front drive axle inner housing components needs to be serviced, refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle) Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle)Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (9.25 Inch HD Axle) Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (9.25 Inch HD Axle).

Installation Procedure




1. Install the inner axle shaft (1).

2. Install the NEW retaining ring (6), and original thrust washer (5) on the inner axle shaft (1).

3. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment (8.6 9.25 Inch Axles) Inner Axle Shaft Shim Adjustment (8.6 9.25 Inch Axles)Inner Axle Shaft Shim Adjustment (9.25 Inch HD axle) Inner Axle Shaft Shim Adjustment (9.25 Inch HD axle).

4. Install the clutch sleeve (7), correct clutch gear shim (8), clutch fork assembly (10), and the clutch fork inner spring (9), in the front drive axle inner shaft housing.





Caution: Refer to Fastener Caution Fastener Caution.

5. Install the front drive axle inner shaft housing assembly (2), gasket (3), and the six bolts (1).

6. Tighten the six front drive axle inner shaft housing bolts (1) to 40 Nm (30 lb ft).




7. Install the front differential carrier bracket nuts (1) and tighten to 100 Nm (74 lb ft).




8. Install the wheel drive shaft bolts (1) and tighten to 79 Nm (58 lb ft).

9. Install the front drive axle actuator. Refer to Front Drive Axle Actuator Replacement Service and Repair.




10. Connect the wire harness (1) to the inner axle shaft housing.




11. Connect the electrical (1) connector to actuator.

12. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Front Axle Lubricant Replacement (8.6/9.25 Inch Axles) Front Axle Lubricant Replacement (8.6/9.25 Inch Axles).

13. Lower the vehicle.