Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement S4WD

Tools Required

J 33799 Clutch Fork Housing Seal Installer

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the right side wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
3. Disconnect the clutch cable from the clutch fork. Refer to Clutch Cable Replacement - Front Drive Axle .



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. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .

1. 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 .



2. Install the new clutch fork seal using the J 33799 .
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. Refer to Clutch Cable Replacement - Front Drive Axle .




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

13. Install the inner axle shaft housing to the frame bracket bolts, washers, and the nuts.

Tighten

•	Tighten the inner axle shaft housing frame bracket nuts to 98 N·m (72 lb ft).

•	Tighten the inner axle shaft housing to differential carrier assembly bolts to 48 N·m (36 lb ft).

14. Install the right side wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
15. Inspect the axle lubricant level and add, if necessary. Refer to Front Axle Lubricant Level Inspection .
16. Lower the vehicle.