Drive Axles - Front: Removal & Installation Chevrolet Silverado 2500

Installation Procedure

Note. Refer to FASTENER NOTICE .

Scheme 386

1. Install the drain plug. Tighten Tighten the drain plug to 33 N.m (24 lb ft).
2. Fill the differential carrier assembly with axle lubricant. Use the proper fluid.
3. Install the fill plug. Tighten Tighten the fill plug to 33 N.m (24 lb ft).
4. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
5. Lower the vehicle.

Scheme 387

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the front differential carrier shield bolts.
3. Remove the front differential carrier shield.

Scheme 388

1. Install the front differential carrier shield. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the front differential carrier shield bolts. Tighten Tighten the front differential carrier shield bolts to 20 N.m (15 lb ft).
3. Lower the vehicle.

Scheme 389

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
3. Disconnect the electrical connector from the actuator (3).
4. Remove the electric motor actuator (3) by turning the actuator counterclockwise.

Scheme 390

1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) to the threads of the electric motor actuator. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the electric motor actuator (3). Tighten Tighten the actuator to 20 N.m (15 lb ft).
3. Connect the electrical connector to the actuator.
4. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
5. Lower the vehicle.

Scheme 391

Scheme 392

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Remove the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) . Important: Make note of the routing in order to aid in reassembly.
3. Remove the vent hose (1) from the wiring bundle (2).
4. Remove the vent hose from the clip.
5. Remove the vent hose from the differential carrier assembly.
6. Remove the vent hose from the vehicle.

Scheme 393

Scheme 394

1. Install the vent hose to the vehicle. Route the vent hose the same way as when removed. Ensure the hose is free of kinks and routes clear of sharp components. Ensure the vent hose is not plugged.
2. Connect the vent hose to the differential carrier assembly.
3. Install the vent hose (1) to the wiring bundle (2).
4. Install the vent hose to the clip.
5. Install the front differential carrier shield, if equipped. Refer to «SHIELD REPLACEMENT»(ref-304051-S21802347052008110500000) .
6. Lower the vehicle.

Removal

1. Apply the park brake.
2. Place the transmission in NEUTRAL.
3. Raise the vehicle. Refer «LIFTING & JACKING THE VEHICLE»(ref-178095) .
4. Remove the left tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-178243-S06885952862005061300000) .
5. Disconnect the vent hose from the vent hose connector.
6. Remove the vent hose connector from the differential carrier assembly.

Scheme 395

Scheme 396

1. Rotate the propeller shaft until the differential case window can be seen through the vent hose connector opening. (Scheme 396): Locating Differential Case Window
2. Place the alignment arm of the vent hose connector in the 6 o'clock position. (Scheme 397): Locating Alignment Arm
3. Install the vent hose connector with the alignment arm in the 6 o'clock position into the vent hose connector opening. Tighten Tighten the vent hose connector to 28 Nm (21 lb ft).
4. Connect the vent hose to the vent hose connector.
5. Install the left tire and wheel assembly. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-178243-S06885952862005061300000).
6. Lower the vehicle.
7. Place the transmission in PARK.
8. Release the park brake.

Scheme 397

Scheme 398

1. Raise the vehicle. Refer «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Disconnect the vent hose from the vent hose connector.
3. Remove the vent hose connector from the differential carrier assembly.

Scheme 399

Scheme 400

1. Install the vent hose connector into the differential carrier assembly. Apply a small amount of sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent onto the threads. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) . Tighten the vent hose connector. Tighten Tighten the vent hose connector to 28 N.m (21 lb ft).
2. Connect the vent hose to the vent hose connector.
3. Lower the vehicle.

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095).
2. Drain the differential carrier assembly. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000).
3. Disconnect the electrical connector from the electric motor actuator.
4. Disconnect the wire harness from the inner axle shaft housing.
5. Remove the stabilizer shaft link assembly. Refer to «STABILIZER SHAFT LINK REPLACEMENT»(ref-178272-S37986554752005061300000).
6. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft. Disconnect the wheel drive shaft from the inner axle shaft.
7. Remove the inner axle shaft housing nuts from the bracket.
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: Remove the front axle mounting bracket to frame nuts. 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. (Scheme 406): Removing Front Axle Mounting Bracket -- Front Drive Axle (8.25 S4WD and 9.25 Axles)
9. Remove the inner axle shaft housing bolts from the differential carrier case. 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. For the 8.25 inch axle - 1st design, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly components (14, 13, 12, 11) The clutch shaft shim (9) Remove the clutch sleeve (8) Remove the clutch gear (6) by doing the following: Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange. 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). Remove the thrust washer (5) (Scheme 409): Inner Axle Shaft Housing Components
12. For the 8.25 inch axle - 2nd design, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly (11) The clutch shaft shim (9) The clutch sleeve (8) The clutch gear (6) by doing the following: Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange. 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). The thrust washer (5)
13. For the 9.25 inch axle - 1st design, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly components (14, 13, 12, 11) The clutch shaft shim (9) The clutch sleeve (8) The retainer ring (7) The thrust washers (5, 6) (Scheme 411): Inner Axle Shaft Housing Components
14. For the 9.25 inch axle - 2nd design, remove the following components from the inner axle shaft housing: The clutch fork inner spring (10) The clutch fork assembly (11) The clutch shaft shim (9) The clutch sleeve (8) The retainer ring (7) The thrust washers (5, 6)
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 «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S40572842342008110500000).

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

1. Install the new inner axle shaft bearing and the seal to the axle housing. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S40572842342008110500000).
2. Install the inner axle shaft (2) into the inner axle shaft housing (1). 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. For the 8.25 inch axle 1st design, install the following components into the inner axle shaft housing: Important: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The retainer ring (7) into the clutch gear (6). The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (14, 13, 12, 11) The clutch fork inner spring (10) into the differential carrier case. see scheme 68: Inner Axle Shaft Housing Components
5. For the 8.25 inch axle 2nd design, install the following components into the inner axle shaft housing: Important: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The retainer ring (7) into the clutch gear (6). The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (11) The clutch fork inner spring (10) into the differential carrier case.
6. For the 9.25 inch axle 1st design, install the following components into the inner axle shaft housing: Important: Use chassis grease in order to hold the thrust washer in place. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The second thrust washer (6) The retainer ring (7) onto the inner axle shaft (1) Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (14, 13,12, 11) The clutch fork inner spring (10) into the differential carrier case. (Scheme 415): Inner Axle Shaft Housing Components
7. For the 9.25 inch axle 2nd design, install the following components into the inner axle shaft housing: The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The second thrust washer (6) The retainer ring (7) onto the inner axle shaft (1). Determine the clutch gear shim thickness. Refer to «INNER AXLE SHAFT SHIM ADJUSTMENT»(ref-304051-S32597037972008110500000). The clutch gear shim (9) The clutch sleeve (8) The clutch fork assembly (11) The clutch fork inner spring (10) into the differential carrier case.
8. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
9. Install the inner axle shaft housing assembly to the differential carrier assembly. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000).
10. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
11. For 25 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle housing: Slide the front axle mounting bracket towards the frame. 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. Install the front axle mounting bracket to frame nuts. Tighten Tighten the front axle mounting bracket to frame nuts to 90 Nm (67 lb ft). (Scheme 418): Front Axle Mounting Bracket -- Front Drive Axle (8.25 S4WD and 9.25 Axles)
12. Install the inner axle shaft housing washers and nuts to the bracket. 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. Install the wheel drive shaft inboard flange to the inner axle shaft bolts. 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»(ref-178272-S37986554752005061300000).
16. Connect the wire harness to the inner axle shaft housing.
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 REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000).
19. Lower the vehicle.

Scheme 421

Scheme 422

Scheme 423

Scheme 424

1. Raise the vehicle. Refer to «LIFTING & JACKING THE VEHICLE»(ref-178095) .
2. Drain the differential carrier assembly. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000) .
3. Remove the stabilizer shaft link assembly. Refer to «STABILIZER SHAFT LINK REPLACEMENT»(ref-178272-S37986554752005061300000) .
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. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift.
7. Remove the inner axle shaft housing nuts from the bracket.
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 «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S40572842342008110500000) .

Scheme 425

Scheme 426

Scheme 427

1. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to «INNER AXLE SEAL AND/OR BEARING REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S40572842342008110500000) .
2. Install the inner axle shaft into the inner axle shaft housing. Do not install the inner axle shaft completely into the inner axle shaft housing at this time.
3. Apply sealant GM P/N 1052942 (Canadian P/N 10953466) or equivalent to the inner axle housing to differential carrier sealing surface.
4. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Install the inner axle shaft housing bolts. Tighten Tighten the inner axle shaft housing bolts to 40 N.m (30 lb ft).
6. Install the inner axle shaft housing nuts to the bracket. 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: Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear. 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. 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. Install the wheel drive shaft inboard flange to inner axle shaft bolts. 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»(ref-178272-S37986554752005061300000) .
11. Fill the differential carrier assembly with axle lubricant. Use the proper fluid. Refer to «LUBRICANT REPLACEMENT - FRONT DRIVE AXLE»(ref-304051-S05702377332008110500000) .
12. Lower the vehicle.

Scheme 428

1. Remove the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000) .
2. Remove the clutch fork assembly (2) from the inner axle shaft housing (1).
3. Remove the clutch fork inner spring from the differential carrier case assembly, if necessary. Take care not to dislodge the inner axle clutch shim from the inner axle shaft.

Scheme 429

1. Install the clutch fork inner spring into the differential carrier case assembly, if necessary.
2. Install the clutch fork assembly (2) into the inner axle shaft housing (1).
3. Install the inner axle shaft and housing assembly. Refer to «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 S4WD AND 9.25 AXLES)»(ref-304051-S25799474842008110500000) or «INNER SHAFT AND/OR HOUSING REPLACEMENT - FRONT DRIVE AXLE (8.25 F4WD AXLE)»(ref-304051-S12356043722008110500000) .