AutoZone 2006 Lexus Truck GX470 4.7L SFI DOHC 8cyl | Repair Guides | Drive Train | Front Drive Axle | Axle Shaft, Bearing & Seal | AutoZone.com

Search suggestions

    My Vehicles

    2006 Lexus Truck GX470 4.7L SFI DOHC 8cyl

    Find a Store

    Select Store

    SAVE 20% ON ONLINE SHIP-TO-HOME ORDERS OF $100 OR MORE.

    Use Code: SEECLEAR

    See Details

    Avalanche, Sierra, Silverado, C&K Series, 1999-2005

    Axle Shaft, Bearing & Seal

    Print

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the front axle.
    4.  
    5. Remove or disconnect the following:

      Electrical connectors, if equipped
       
      Drive axle (halfshaft)
       
      Axle shaft (output shaft)
       
      Axle shaft from case
       
      Deflector and seal
       
      Bearing
       

    6.  

    To install:

    1. Install or connect the following:
      NOTE
      Lubricate the new seal with grease.



      New Bearing, square shoulder in
       



      New seal
       
      Deflector
       
      Axle shaft (output shaft)
       
      Drive axle (halfshaft)
       
      Electrical connectors, if equipped
       

    2.  
    3. Refill the front axle.
    4.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the front axle.
    4.  
    5. Remove or disconnect the following:

      Electrical connectors, if equipped
       
      Drive axle (halfshaft)
       
      Axle shaft (output shaft)
       
      Axle shaft from case
       
      Deflector and seal
       
      Bearing
       

    6.  

    To install:

    1. Install or connect the following:
      NOTE
      Lubricate the new seal with grease.



      New Bearing, square shoulder in
       



      New seal
       
      Deflactor
       
      Axle shaft (output shaft)
       
      Drive axle (halfshaft)
       
      Electrical connectors, if equipped
       

    2.  
    3. Refill the front axle.
    4.  

    8.25 in. F4WD (Full-Time) Axle
    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 16.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    10.  
    11. Disconnect the wheel drive shaft from the inner axle shaft.
    12.  
    13. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift. Remove the inner axle shaft housing nuts from the bracket.
    14.  
    15. Remove the inner axle shaft housing bolts from the differential carrier assembly.
    16.  
    17. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
    18.  
    19. Remove the inner axle shaft from the inner axle shaft housing.
    20.  
    21. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing.
    22.  
    23. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    24.  
    25. Install the bushing and bearing removal tool J-29369-1 behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    26.  
    27. Install a slide hammer to the removal tool.
    28.  
    29. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    30.  
    31. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    32.  
    33. Disconnect the wheel drive shaft from the inner axle shaft.
    34.  
    35. Remove the inner axle shaft using a hammer and a brass drift.
    36.  
    37. Remove the inner axle shaft seal using a suitable seal remover tool.
    38.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps.
    20.  
    21. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing.
    22.  
    23. 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.
    24.  
    25. Apply sealant to the inner axle housing to differential carrier sealing surface.
    26.  
    27. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
    28.  
    29. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm).
    30.  
    31. Install the inner axle shaft housing nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    32.  
    33. Install the inner axle shaft into the differential case side gear by doing the following:
    34.  
    35. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    36.  
    37. 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.
    38.  
    39. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    40.  
    41. Install the wheel drive shaft inboard flange to the inner axle shaft.
    42.  
    43. Install the wheel drive shaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    44.  
    45. Install the stabilizer shaft link assembly.
    46.  
    47. Fill the differential carrier assembly with axle lubricant
    48.  
    49. Lower the vehicle.
    50.  

    8.25 in. S4WD (Part-Time) & 9.25 in. Axles
    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 19.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Disconnect the electrical connector from the electric motor actuator.
    10.  
    11. Disconnect the wire harness from the inner axle shaft housing.
    12.  
    13. Remove the drive shaft inboard flange bolts from the inner axle shaft.
    14.  
    15. Disconnect the wheel drive shaft from the inner axle shaft.
    16.  
    17. Remove the inner axle shaft housing nuts from the bracket.
    18.  
    19. For 2500 series vehicles, remove the front axle mounting bracket to frame nuts.
    20.  
    21. Slide the front axle mounting bracket toward 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.
    22.  
    23. Remove the inner axle shaft housing bolts from the differential carrier case.
    24.  
    25. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
    26.  
    27. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The clutch gear (6) by doing the following:
      10.  
      11. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
      12.  
      13. 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).
      14.  
      15. The thrust washer (5).
      16.  

    28.  
    29. For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The retainer ring (7).
      10.  
      11. The thrust washers (5, 6).

        Click image to see an enlarged view

        Fig. Exploded view of the front axle assembly-8.25 S4WD and 9.25 axles

      12.  

    30.  
    31. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
    32.  
    33. Remove the inner axle seal and the bearing from the axle housing.
    34.  
    35. If only replacing the left side inner axle shaft, remove the wheel drive shaft inboard flange bolts from the inner axle shaft. Disconnect the wheel drive shaft from the inner axle shaft.
    36.  
    37. Remove the inner axle shaft using a hammer and a brass drift.
    38.  
    39. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    40.  
    41. Install the bushing and bearing removal tool J-29369-1, 8.25 inch axle, or J-29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    42.  
    43. Install a slide hammer to the removal tool.
    44.  
    45. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    46.  
    47. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    48.  
    49. Disconnect the wheel drive shaft from the inner axle shaft.
    50.  
    51. Remove the inner axle shaft using a hammer and a brass drift.
    52.  
    53. Remove the inner axle shaft seal using a suitable seal remover tool.
    54.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps:
    20.  
    21. Install the new inner axle shaft bearing and the seal to the axle housing.
    22.  
    23. 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.
    24.  
    25. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
    26.  
    27. For the 8.25 inch axle, install the following components into the inner axle shaft housing:
      NOTE
      Use chassis grease in order to hold the thrust washer in place.

    28.  
    29. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    30.  
    31. The retainer ring (7) into the clutch gear (6).
    32.  
    33. The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer.
    34.  
    35. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place.
    36.  
    37. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time.
    38.  
    39. Install the bolts.
    40.  
    41. Install a dial indicator on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange.
    42.  
    43. Move the shaft back and forth and read the end play. The correct end play is 0.001-0.020 in (0.03-0.51mm).
    44.  
    45. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.
    46.  
    47. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    48.  
    49. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
    50.  
    51. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    52.  
    53. The second thrust washer (6).
    54.  
    55. The retainer ring (7) onto the inner axle shaft (1).
    56.  
    57. Determine the clutch gear shim thickness.
    58.  
    59. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    60.  
    61. Apply sealant to the inner axle housing to differential carrier sealing surface.
    62.  
    63. Install the inner axle shaft housing assembly to the differential carrier assembly.
    64.  
    65. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm) or 41 ft. lbs. (55 Nm) on 2007 models with 9.25 inch axles.
    66.  
    67. For 2500 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
    68.  
    69. Slide the front axle mounting bracket toward 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 bracket studs into the inner shaft housing.
    70.  
    71. Install the front axle mounting bracket to frame nuts. Tighten to 67 ft. lbs. (90 Nm).
    72.  
    73. Install the inner axle shaft housing washers and nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    74.  
    75. Connect the wheel drive shaft inboard flange to the inner axle shaft and tighten to . 30 ft. lbs. (40 Nm).
    76.  
    77. Install the wheel drive shaft inboard flange to the inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    78.  
    79. Connect the wire harness to the inner axle shaft housing.
    80.  
    81. Connect the electrical connector to the front axle actuator.
    82.  
    83. Install the stabilizer shaft link assembly.
    84.  
    85. With either replacement procedure, fill the differential carrier assembly with axle lubricant.
    86.  
    87. Lower the vehicle.
    88.  

    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 19.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Disconnect the electrical connector from the electric motor actuator.
    10.  
    11. Disconnect the wire harness from the inner axle shaft housing.
    12.  
    13. Remove the drive shaft inboard flange bolts from the inner axle shaft.
    14.  
    15. Disconnect the wheel drive shaft from the inner axle shaft.
    16.  
    17. Remove the inner axle shaft housing nuts from the bracket.
    18.  
    19. For 2500/3500 series vehicles, remove the front axle mounting bracket to frame nuts.
    20.  
    21. 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.
    22.  
    23. Remove the inner axle shaft housing bolts from the differential carrier case.
    24.  
    25. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
    26.  
    27. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The clutch gear (6) by doing the following:
      10.  
      11. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
      12.  
      13. 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).
      14.  
      15. The thrust washer (5).
      16.  

    28.  
    29. For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The retainer ring (7).
      10.  
      11. The thrust washers (5, 6).

        Click image to see an enlarged view

        Fig. Exploded view of the front axle assembly-8.25 S4WD and 9.25 axles

      12.  

    30.  
    31. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
    32.  
    33. Remove the inner axle seal and the bearing from the axle housing.
    34.  
    35. If only replacing the left side inner axle shaft, remove the wheel drive shaft inboard flange bolts from the inner axle shaft. Disconnect the wheel drive shaft from the inner axle shaft.
    36.  
    37. Remove the inner axle shaft using a hammer and a brass drift.
    38.  
    39. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    40.  
    41. Install the bushing and bearing removal tool J-29369-1, 8.25 inch axle, or J-29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    42.  
    43. Install a slide hammer to the removal tool.
    44.  
    45. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    46.  
    47. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    48.  
    49. Disconnect the wheel drive shaft from the inner axle shaft.
    50.  
    51. Remove the inner axle shaft using a hammer and a brass drift.
    52.  
    53. Remove the inner axle shaft seal using a suitable seal remover tool.
    54.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps:
    20.  
    21. Install the new inner axle shaft bearing and the seal to the axle housing.
    22.  
    23. 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.
    24.  
    25. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
    26.  
    27. For the 8.25 inch axle, install the following components into the inner axle shaft housing:
      NOTE
      Use chassis grease in order to hold the thrust washer in place.

    28.  
    29. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    30.  
    31. The retainer ring (7) into the clutch gear (6).
    32.  
    33. The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer.
    34.  
    35. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place.
    36.  
    37. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time.
    38.  
    39. Install the bolts.
    40.  
    41. Install a dial indicator on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange.
    42.  
    43. Move the shaft back and forth and read the end play. The correct end play is 0.001-0.020 in (0.03-0.51mm).
    44.  
    45. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.
    46.  
    47. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    48.  
    49. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
    50.  
    51. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    52.  
    53. The second thrust washer (6).
    54.  
    55. The retainer ring (7) onto the inner axle shaft (1).
    56.  
    57. Determine the clutch gear shim thickness.
    58.  
    59. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    60.  
    61. Apply sealant to the inner axle housing to differential carrier sealing surface.
    62.  
    63. Install the inner axle shaft housing assembly to the differential carrier assembly.
    64.  
    65. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm) or 41 ft. lbs. (55 Nm) on 2007 models (except Classic) with 9.25 inch axles.
    66.  
    67. For 2500/3500 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
    68.  
    69. 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 bracket studs into the inner shaft housing.
    70.  
    71. Install the front axle mounting bracket to frame nuts. Tighten to 67 ft. lbs. (90 Nm).
    72.  
    73. Install the inner axle shaft housing washers and nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    74.  
    75. Connect the wheel drive shaft inboard flange to the inner axle shaft and tighten to . 30 ft. lbs. (40 Nm).
    76.  
    77. Install the wheel drive shaft inboard flange to the inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    78.  
    79. Connect the wire harness to the inner axle shaft housing.
    80.  
    81. Connect the electrical connector to the front axle actuator.
    82.  
    83. Install the stabilizer shaft link assembly.
    84.  
    85. With either replacement procedure, fill the differential carrier assembly with axle lubricant.
    86.  
    87. Lower the vehicle.
    88.  

    8.25 inch F4wd Axle
    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 16.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    10.  
    11. Disconnect the wheel drive shaft from the inner axle shaft.
    12.  
    13. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift. Remove the inner axle shaft housing nuts from the bracket.
    14.  
    15. Remove the inner axle shaft housing bolts from the differential carrier assembly.
    16.  
    17. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
    18.  
    19. Remove the inner axle shaft from the inner axle shaft housing.
    20.  
    21. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing.
    22.  
    23. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    24.  
    25. Install the bushing and bearing removal tool J-29369-1, 8.25 inch axle, or J-29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    26.  
    27. Install a slide hammer to the removal tool.
    28.  
    29. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    30.  
    31. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    32.  
    33. Disconnect the wheel drive shaft from the inner axle shaft.
    34.  
    35. Remove the inner axle shaft using a hammer and a brass drift.
    36.  
    37. Remove the inner axle shaft seal using a suitable seal remover tool.
    38.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps.
    20.  
    21. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing.
    22.  
    23. 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.
    24.  
    25. Apply sealant to the inner axle housing to differential carrier sealing surface.
    26.  
    27. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
    28.  
    29. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm).
    30.  
    31. Install the inner axle shaft housing nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    32.  
    33. Install the inner axle shaft into the differential case side gear by doing the following:
    34.  
    35. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    36.  
    37. 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.
    38.  
    39. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    40.  
    41. Install the wheel drive shaft inboard flange to the inner axle shaft.
    42.  
    43. Install the wheel drive shaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    44.  
    45. Install the stabilizer shaft link assembly.
    46.  
    47. Fill the differential carrier assembly with axle lubricant
    48.  
    49. Lower the vehicle.
    50.  

    8.25 inch S4wd & 9.25 inch Axles
    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 19.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Disconnect the electrical connector from the electric motor actuator.
    10.  
    11. Disconnect the wire harness from the inner axle shaft housing.
    12.  
    13. Remove the drive shaft inboard flange bolts from the inner axle shaft.
    14.  
    15. Disconnect the wheel drive shaft from the inner axle shaft.
    16.  
    17. Remove the inner axle shaft housing nuts from the bracket.
    18.  
    19. For 25/35 series vehicles, remove the front axle mounting bracket to frame nuts.
    20.  
    21. 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.
    22.  
    23. Remove the inner axle shaft housing bolts from the differential carrier case.
    24.  
    25. Carefully remove the inner axle shaft housing assembly from the differential carrier assembly.
    26.  
    27. For the 8.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The clutch gear (6) by doing the following:
      10.  
      11. Clamp the inner axle shaft housing (4) in a vise. Clamp only on the mounting flange.
      12.  
      13. 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).
      14.  
      15. The thrust washer (5).
      16.  

    28.  
    29. For the 9.25 inch axle, remove the following components from the inner axle shaft housing:
      1. The clutch fork inner spring (10).
      2.  
      3. The clutch fork assembly (11).
      4.  
      5. The clutch shaft shim (9).
      6.  
      7. The clutch sleeve (8).
      8.  
      9. The retainer ring (7).
      10.  
      11. The thrust washers (5, 6).

        Click image to see an enlarged view

        Fig. Exploded view of the front axle assembly-8.25 S4WD and 9.25 axles

      12.  

    30.  
    31. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
    32.  
    33. Remove the inner axle seal and the bearing from the axle housing.
    34.  
    35. If only replacing the left side inner axle shaft, remove the wheel drive shaft inboard flange bolts from the inner axle shaft. Disconnect the wheel drive shaft from the inner axle shaft.
    36.  
    37. Remove the inner axle shaft using a hammer and a brass drift.
    38.  
    39. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    40.  
    41. Install the bushing and bearing removal tool J-29369-1, 8.25 inch axle, or J-29369-2, 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    42.  
    43. Install a slide hammer to the removal tool.
    44.  
    45. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    46.  
    47. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    48.  
    49. Disconnect the wheel drive shaft from the inner axle shaft.
    50.  
    51. Remove the inner axle shaft using a hammer and a brass drift.
    52.  
    53. Remove the inner axle shaft seal using a suitable seal remover tool.
    54.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps:
    20.  
    21. Install the new inner axle shaft bearing and the seal to the axle housing.
    22.  
    23. 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.
    24.  
    25. Place the inner axle shaft housing on end so that the splines of the inner axle shaft is facing up.
    26.  
    27. For the 8.25 inch axle, install the following components into the inner axle shaft housing:
      NOTE
      Use chassis grease in order to hold the thrust washer in place.

    28.  
    29. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    30.  
    31. The retainer ring (7) into the clutch gear (6).
    32.  
    33. The clutch gear (6) onto the inner axle shaft (1). Drive the clutch gear into place with a plastic hammer.
    34.  
    35. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place.
    36.  
    37. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time.
    38.  
    39. Install the bolts and tighten to 30 ft. lbs. (40 Nm).
    40.  
    41. Install a dial indicator on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange.
    42.  
    43. Move the shaft back and forth and read the end play. The correct end play is 0.001-0.020 in (0.03-0.51mm).
    44.  
    45. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.
    46.  
    47. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    48.  
    49. For the 9.25 inch axle, install the following components into the inner axle shaft housing:
    50.  
    51. The thrust washer (5) Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4).
    52.  
    53. The second thrust washer (6).
    54.  
    55. The retainer ring (7) onto the inner axle shaft (1).
    56.  
    57. Determine the clutch gear shim thickness.
    58.  
    59. Install the clutch gear shim (9). clutch sleeve (8), clutch fork assembly (11) and clutch fork inner spring (10).
    60.  
    61. Apply sealant to the inner axle housing to differential carrier sealing surface.
    62.  
    63. Install the inner axle shaft housing assembly to the differential carrier assembly.
    64.  
    65. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm).
    66.  
    67. For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
    68.  
    69. 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 bracket studs into the inner shaft housing.
    70.  
    71. Install the front axle mounting bracket to frame nuts.
    72.  
    73. Install the inner axle shaft housing washers and nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    74.  
    75. Connect the wheel drive shaft inboard flange to the inner axle shaft and tighten to . 30 ft. lbs. (40 Nm).
    76.  
    77. Install the wheel drive shaft inboard flange to the inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    78.  
    79. Connect the wire harness to the inner axle shaft housing.
    80.  
    81. Connect the electrical connector to the front axle actuator.
    82.  
    83. Install the stabilizer shaft link assembly.
    84.  
    85. With either replacement procedure, fill the differential carrier assembly with axle lubricant.
    86.  
    87. Lower the vehicle.
    88.  

    AWD (Full-Time) Axle
    1. Raise and support the vehicle.
    2.  
    3. Drain the differential carrier assembly.
    4.  
    5. If only replacing the right side inner shaft and/or housing, follow the steps below. If only replacing the left side inner shaft, proceed to step 16.
    6.  
    7. Remove the stabilizer shaft link assembly.
    8.  
    9. Remove the wheel drive shaft inboard flange bolts from the inner axle shaft.
    10.  
    11. Disconnect the wheel drive shaft from the inner axle shaft.

      Click image to see an enlarged view

      Fig. Removing the drive shaft from the inner axle shaft

    12.  
    13. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift. Remove the inner axle shaft housing nuts from the bracket.
    14.  
    15. Remove the inner axle shaft housing bolts from the differential carrier assembly.
    16.  
    17. Remove the inner axle shaft and inner axle shaft housing from the vehicle.
    18.  
    19. Remove the inner axle shaft from the inner axle shaft housing.
    20.  
    21. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing.

      Click image to see an enlarged view

      Fig. Inner axle shaft seal and bearing cover

    22.  
    23. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
    24.  
    25. Install the bushing and bearing removal tool J-29369-1 behind the inner axle shaft seal or the inner axle shaft bearing as necessary.
    26.  
    27. Install a slide hammer to the removal tool.
    28.  
    29. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the slide hammer.
    30.  
    31. If only replacing the left side seal, place an alignment mark between the inner axle shaft and the wheel drive shaft.
    32.  
    33. Disconnect the wheel drive shaft from the inner axle shaft.
    34.  
    35. Remove the inner axle shaft using a hammer and a brass drift.
    36.  
    37. Remove the inner axle shaft seal using a suitable seal remover tool.
    38.  

    To install:

    1. Install the right side bearing with the square shoulder in using and axle bearing tube installer and a universal driver handle.
    2.  
    3. Install the new axle shaft seal using the sane tools.
    4.  
    5. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet.
    6.  
    7. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing.
    8.  
    9. If only the left side inner axle shaft was removed, install the shaft by performing the following steps:
    10.  
    11. 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.
    12.  
    13. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    14.  
    15. Connect the halfshaft to the inner axle shaft.
    16.  
    17. Install the halfshaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    18.  
    19. If the right side inner axle shaft and/or housing was removed, install the shaft and/or housing using the following steps.
    20.  
    21. Install the new inner axle shaft bearing and the new seal to the inner axle shaft housing.
    22.  
    23. 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.
    24.  
    25. Apply sealant to the inner axle housing to differential carrier sealing surface.
    26.  
    27. Install the inner axle shaft and the inner axle shaft housing to the differential carrier assembly.
    28.  
    29. Install the inner axle shaft housing bolts and tighten to 30 ft. lbs. (40 Nm).
    30.  
    31. Install the inner axle shaft housing nuts to the bracket and tighten to 75 ft. lbs. (100 Nm).
    32.  
    33. Install the inner axle shaft into the differential case side gear by doing the following:
    34.  
    35. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
    36.  
    37. 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.
    38.  
    39. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear.
    40.  
    41. Install the wheel drive shaft inboard flange to the inner axle shaft.
    42.  
    43. Install the wheel drive shaft inboard flange to inner axle shaft bolts and tighten to 58 ft. lbs. (79 Nm).
    44.  
    45. Install the stabilizer shaft link assembly.
    46.  
    47. Fill the differential carrier assembly with axle lubricant
    48.  
    49. Lower the vehicle.
    50.  

     
    AutoZone Logo