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Makes 🢒 Chevrolet 🢒 2002 🢒 Chevy Suburban - 4WD 🢒 General Information 🢒 General Information 🢒 Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement

Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement 8.25 S4WD and 9.25 Axles

Removal Procedure

    Object Number: 834234 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Drain the differential carrier assembly. Refer to Lubricant Change .
  3. Disconnect the electrical connector from the electric motor actuator.

    4. Object Number: 834265 Size: SH
  4. Disconnect the wire harness from the inner axle shaft housing.
  5. Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    6. Object Number: 763646 Size: SH
  6. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.

    7. Disconnect the wheel drive shaft from the inner axle shaft.


    Object Number: 834241 Size: SH
  7. Remove the inner axle shaft housing nuts and washers from the bracket.

    8. Object Number: 365933 Size: SH
  8. For 25 series vehicles, perform the following steps in order to provide additional clearance so the inner axle housing can be removed from the vehicle:
    9. 8.1. Remove the front axle mounting bracket to frame nuts.
    8.2. Slide the front axle mounting bracket towards the engine. It may be necessary to pull down on the inner axle housing and/or push up on the mounting bracket in order to gain clearance.

    Object Number: 834261 Size: SH
  9. Remove the inner axle shaft housing bolts from the differential carrier case.

    10. Object Number: 615922 Size: SH

    Important: Keep the open end of the inner axle shaft housing up.

  10. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.

    11. Object Number: 695177 Size: SH
  11. For the 8.25 inch axle - 1st design, remove the following components from the inner axle shaft housing:
    12. 11.1. The clutch fork inner spring (10)
    11.2. The clutch fork shaft assembly components (14, 13, 12, 11)
    11.3. The clutch shaft shim (9)
    11.4. Remove the clutch sleeve (8)
    11.5. Remove the clutch gear (6) by doing the following:
             11.5.1. Clamp the inner axle shaft housing (4) in a vise.

    Clamp only on the mounting flange.

             11.5.2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear 6) from the inner axle shaft (1).
    11.6. Remove the thrust washer (5)

    Object Number: 892810 Size: SH
  12. For the 8.25 inch axle - 2nd design, remove the following components from the inner axle shaft housing:
    13. 12.1. The clutch fork inner spring (10)
    12.2. The clutch fork assembly (11)
    12.3. The clutch shaft shim (9)
    12.4. The clutch sleeve (8)
    12.5. The clutch gear (6) by doing the following:
             12.5.1. Clamp the inner axle shaft housing (4) in a vise.

    Clamp only on the mounting flange.

             12.5.2. Strike the inside surface of the shaft (1) flange with a hammer and a brass drift in order to dislodge the front drive axle clutch gear (6) from the inner axle shaft (1).
    12.6. The thrust washer (5)

    Object Number: 695181 Size: SH
  13. For the 9.25 inch axle - 1st design, remove the following components from the inner axle shaft housing:
    14. 13.1. The clutch fork inner spring (10)
    13.2. The clutch fork assembly components (14, 13, 12, 11)
    13.3. The clutch shaft shim (9)
    13.4. The clutch sleeve (8)
    13.5. The retainer ring (7)
    13.6. The thrust washers (5, 6)

    Object Number: 892812 Size: SH
  14. For the 9.25 inch axle - 2nd design, remove the following components from the inner axle shaft housing:
    15. 14.1. The clutch fork inner spring (10)
    14.2. The clutch fork assembly (11)
    14.3. The clutch shaft shim (9)
    14.4. The clutch sleeve (8)
    14.5. The retainer ring (7)
    14.6. The thrust washers (5, 6)

    Object Number: 615683 Size: SH
  15. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet.
  16. Remove the inner axle seal and the bearing from the axle housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .

Installation Procedure
  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. Object Number: 615683 Size: SH
  2. Install the inner axle shaft (2) into the inner axle shaft housing (1).

    3. Carefully tap the inner axle shaft into place with a soft-faced mallet.

  3. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.

    4. Object Number: 695177 Size: SH
  4. For the 8.25 inch axle - 1st design, install the following components into the inner axle shaft housing:

    5.         Important: Use chassis grease in order to hold the thrust washer in place.

    4.1. The thrust washer (5)

    Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    4.2. The retainer ring (7) into the clutch gear (6).
    4.3. The clutch gear (6) onto the inner axle shaft (1).

    Drive the clutch gear into place with a plastic hammer.

    4.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    4.5. The clutch gear shim (9)
    4.6. The clutch sleeve (8)
    4.7. The clutch fork assembly (14, 13, 12, 11)
    4.8. The clutch fork inner spring (10) into the differential carrier case.

    Object Number: 892810 Size: SH
  5. For the 8.25 inch axle - 2nd design, install the following components into the inner axle shaft housing:

    6.         Important: Use chassis grease in order to hold the thrust washer in place.

    5.1. The thrust washer (5)

    Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    5.2. The retainer ring (7) into the clutch gear (6).
    5.3. The clutch gear (6) onto the inner axle shaft (1).

    Drive the clutch gear into place with a plastic hammer.

    5.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    5.5. The clutch gear shim (9)
    5.6. The clutch sleeve (8)
    5.7. The clutch fork assembly (11)
    5.8. The clutch fork inner spring (10) into the differential carrier case.

    Object Number: 695181 Size: SH
  6. For the 9.25 inch axle - 1st design, install the following components into the inner axle shaft housing:

    7.         Important: Use chassis grease in order to hold the thrust washer in place.

    6.1. The thrust washer (5)

    Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    6.2. The second thrust washer (6)
    6.3. The retainer ring (7) onto the inner axle shaft (1).
    6.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    6.5. The clutch gear shim (9)
    6.6. The clutch sleeve (8)
    6.7. The clutch fork assembly (14, 13, 12, 11)
    6.8. The clutch fork inner spring (10) into the differential carrier case.

    Object Number: 892812 Size: SH
  7. For the 9.25 inch axle - 2nd design, install the following components into the inner axle shaft housing:

    8.         Important: Use chassis grease in order to hold the thrust washer in place.

    7.1. The thrust washer (5)

    Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).

    7.2. The second thrust washer (6)
    7.3. The retainer ring (7) onto the inner axle shaft (1).
    7.4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
    7.5. The clutch gear shim (9)
    7.6. The clutch sleeve (8)
    7.7. The clutch fork assembly (11)
    7.8. The clutch fork inner spring (10) into the differential carrier case.
  8. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .

    9. Object Number: 893259 Size: SH
  9. Install the inner axle shaft housing assembly to the differential carrier assembly.

    10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 834261 Size: SH
  10. Install the inner axle shaft housing bolts.

    11. Tighten
    Tighten the inner axle shaft housing bolts to 40 N·m  (30 lb ft).


    Object Number: 365933 Size: SH
  11. For 25 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle housing:
    12. 11.1. Slide the front axle mounting bracket towards the frame.
    11.2. 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 brackets studs into the inner shaft housing.

    11.3. Install the front axle mounting bracket to frame nuts.

    Tighten
    Tighten the front axle mounting bracket to frame nuts to 90 N·m (67 lb ft).


    Object Number: 834241 Size: SH
  12. Install the inner axle shaft housing washers and nuts to the bracket.

    13. Tighten
    Tighten the inner axle shaft housing nuts to 100 N·m (75 lb ft).

  13. Connect the wheel drive shaft inboard flange to the inner axle shaft.

    14. Object Number: 763646 Size: SH
  14. Install the wheel drive shaft inboard flange to the inner axle shaft bolts.

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

  15. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    16. Object Number: 834265 Size: SH
  16. Connect the wire harness to the inner axle shaft housing.

    17. Object Number: 834234 Size: SH
  17. Connect the electrical connector to the front axle actuator.
  18. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Change .
  19. Lower the vehicle.

Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement 8.25 F4WD Axle

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Drain the differential carrier assembly. Refer to Lubricant Change .
  3. Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

    4. Object Number: 763646 Size: SH
  4. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
  5. Disconnect the wheel drive shaft from the inner axle shaft.

    6. Object Number: 763648 Size: SH
  6. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift.

    7. Object Number: 763653 Size: SH
  7. Remove the inner axle shaft housing nuts and washers from the bracket.

    8. Object Number: 763644 Size: SH
  8. Remove the inner axle shaft housing bolts from the differential carrier assembly.
  9. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
  10. Remove the inner axle shaft from the inner axle shaft housing.
  11. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .

Installation Procedure
  1. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .
  2. Install the inner axle shaft into the inner axle shaft housing.

    3. Do not install the inner axle shaft completely into the inner axle shaft housing at this time.

  3. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
  4. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.

    5. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 763644 Size: SH
  5. Install the inner axle shaft housing bolts.

    6. Tighten
    Tighten the inner axle shaft housing bolts to 40 N·m  (30 lb ft).


    Object Number: 763653 Size: SH
  6. Install the inner axle shaft housing nuts and washers to the bracket.

    7. Tighten
    Tighten the inner axle shaft housing nuts to 100 N·m (75 lb ft).

  7. Install the inner axle shaft into the differential case side gear by doing the following:
    8. 7.1. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    7.2. 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.
    7.3. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
  8. Install the wheel drive shaft inboard flange to the inner axle shaft.

    9. Object Number: 763646 Size: SH
  9. Install the wheel drive shaft inboard flange to inner axle shaft bolts.

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

  10. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  11. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to Lubricant Change .
  12. Lower the vehicle.