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Old 02-03-2009, 04:25 PM   #1
Country Boy
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Default Complete disassembly and reassembly of a IFS front axle.

This is straight from the GM Tech manual on how they do it. If you are mechanically inclined, you dont need the Jxxxxx tools as they are Kent More (expensive) tools.

Please noone post until I have finished all the posts. It will be a long and cover 8.25 and 9.25 axles. Pictures will come at a later date!

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Old 02-03-2009, 04:25 PM   #2
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Lubricant Level Inspection - Front Drive Axle

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Make sure the vehicle is level.
3. Inspect the front axle for leaks. Repair as necessary.
4. Clean the area around the front axle fill plug.



5. Remove the front axle fill plug (1).
6. Inspect the oil level.
Specification
* For the 8.25 inch axle, the oil level should be between 12-16 mm (0.50-0.625 in) below the fill plug opening.
* For the 9.25 inch axle, the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening.
7. If the level is low, add oil until the level is between 12-16 mm (0.50-0.625 in) for the 8.25 inch axle or 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Sealers, Adhesives, and Lubricants .
Notice

Refer to Fastener Notice in Cautions and Notices.
8. Install the fill plug.
Tighten

Tighten the plug to 33 N·m (24 lb ft).
9. Lower the vehicle.
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Old 02-03-2009, 04:26 PM   #3
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Lubricant Replacement - Front Drive Axle
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .
3. Clean the area around the front axle fill plug and the drain plug.
4. Remove the fill plug.



5. Remove the drain plug.
6. Drain the fluid from the front differential carrier assembly.

Installation Procedure

Notice

Refer to Fastener Notice in Cautions and Notices.



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 correct fluid. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication and Sealers, Adhesives, and Lubricants .
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 .
5. Lower the vehicle.
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Old 02-03-2009, 04:27 PM   #4
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Shield Replacement
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the front differential carrier shield bolts.
3. Remove the front differential carrier shield.

Installation Procedure




1. Install the front differential carrier shield.

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.
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.
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Old 02-03-2009, 04:28 PM   #5
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Electric Motor Actuator Replacement
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .
3. Disconnect the electrical connector from the actuator.



4. Remove the electric motor actuator (3) by turning the actuator counterclockwise.

Installation Procedure

1. Apply sealant to the threads of the electric motor actuator. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .
Notice

Refer to Fastener Notice in Cautions and Notices.



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 .
5. Lower the vehicle.
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Old 02-03-2009, 04:28 PM   #6
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Vent Hose Replacement
Removal Procedure




1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front differential carrier shield, if equipped. Refer to Shield Replacement .

Important

Make note of the routing in order to aid in reassembly.
3. Remove the vent hose (1) from the wiring bundle (2), S4WD axles only.
4. Remove the vent hose from the retainer clips, all axles.



5. Remove the vent hose from the differential carrier assembly.
6. Remove the vent hose from the vehicle.

Installation Procedure




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), S4WD axles only.
4. Install the vent hose to the retainer clips, all axles.
5. Install the front differential carrier shield, if equipped. Refer to Shield Replacement .
6. Lower the vehicle.
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Old 02-03-2009, 04:29 PM   #7
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Vent Hose Connector Replacement - Front Drive Axle
Removal Procedure

1. Raise the vehicle. Refer Lifting and Jacking the Vehicle in General Information.



2. Disconnect the vent hose from the vent hose connector.



3. Remove the vent hose connector from the differential carrier assembly.

Installation Procedure




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.
Notice

Refer to Fastener Notice in Cautions and Notices.
2. Tighten the vent hose connector.
Tighten

Tighten the vent hose connector to 28 N·m (21 lb ft).



3. Connect the vent hose to the vent hose connector.
4. Lower the vehicle.
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Old 02-03-2009, 04:30 PM   #8
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Inner Shaft and/or Housing Replacement - Front Drive Axle 8.25 S4WD and 9.25 Axles
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 Replacement - Front Drive Axle .
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 in Front Suspension.



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 25/35 series vehicles, perform the following steps in order to provide additional clearance so the inner axle housing can be removed from the vehicle:
1. Remove the front axle mounting bracket to frame nuts.
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.



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, remove the following components from the inner axle shaft housing:
1. The clutch fork inner spring (10)
2. The clutch fork assembly (11)
3. The clutch shaft shim (9)
4. The clutch sleeve (8)
5. The clutch gear (6) by doing the following:
1. Clamp the inner axle shaft housing (4) in a vise.
2. 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).
6. The thrust washer (5)



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



13. Remove the inner axle shaft (2). Tap out the inner axle shaft with a soft-faced mallet, if necessary.
14. Remove the inner axle seal and the bearing from the axle housing. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .

Installation Procedure

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 .



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. 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, install the following components into the inner axle shaft housing:

Important

Use chassis grease in order to hold the thrust washer in place.
1. The thrust washer (5)
2. 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).
3. The clutch gear (6) onto the inner axle shaft (1).
4. Drive the clutch gear into place with a plastic hammer. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
5. The clutch gear shim (9)
6. The clutch sleeve (8)
7. The clutch fork assembly (11)
8. The clutch fork inner spring (10)



5. For the 9.25 inch axle, install the following components into the inner axle shaft housing:

Important

Use chassis grease in order to hold the thrust washer in place.
1. The thrust washer (5)
2. Ensure the tabs on the thrust washer are aligned with the slots in the inner axle shaft housing (4). The second thrust washer (6)
3. The retainer ring (7) onto the inner axle shaft (1).
4. Determine the clutch gear shim thickness. Refer to Inner Axle Shaft Shim Adjustment .
5. The clutch gear shim (9)
6. The clutch sleeve (8)
7. The clutch fork assembly (11)
8. The clutch fork inner spring (10)
6. Apply sealant to the inner axle housing to differential carrier sealing surface. Use the correct sealant. Refer to Sealers, Adhesives, and Lubricants .



7. Install the inner axle shaft housing assembly to the differential carrier assembly.
Notice

Refer to Fastener Notice in Cautions and Notices.



8. Install the inner axle shaft housing bolts.
Tighten

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



9. For 25/35 series vehicles, perform the following steps in order to install the front axle mounting bracket to the inner axle shaft housing:
1. Slide the front axle mounting bracket towards the frame.
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 bracket studs into the inner shaft housing. Install the front axle mounting bracket to frame nuts.
Tighten

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



10. 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).
11. Connect the wheel drive shaft inboard flange to the inner axle shaft.



12. 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).
13. Install the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.



14. Connect the wire harness to the inner axle shaft housing.



15. Connect the electrical connector to the front axle actuator.
16. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
17. Lower the vehicle.
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Old 02-03-2009, 04:31 PM   #9
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Inner Shaft and/or Housing Replacement - Front Drive Axle 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 Replacement - Front Drive Axle .
3. Remove the stabilizer shaft link assembly. Refer to Stabilizer Shaft Link Replacement in Front Suspension.

Object Number: 763646 Size: SH
Click here for detailed picture of above image.
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.

Object Number: 763648 Size: SH
Click here for detailed picture of above image.
6. Disconnect the inner axle shaft from the differential case side gear using a hammer and brass drift.

Object Number: 763653 Size: SH
Click here for detailed picture of above image.
7. Remove the inner axle shaft housing nuts from the bracket.

Object Number: 763644 Size: SH
Click here for detailed picture of above image.
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 .

Installation Procedure

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 .
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. 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.
Notice

Refer to Fastener Notice in Cautions and Notices.

Object Number: 763644 Size: SH
Click here for detailed picture of above image.
5. Install the inner axle shaft housing bolts.
Tighten

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

Object Number: 763653 Size: SH
Click here for detailed picture of above image.
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:
1. Turn the inner axle shaft and align the splines of the inner axle shaft with the splines on the differential side gear.
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.
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.

Object Number: 763646 Size: SH
Click here for detailed picture of above image.
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 in Front Suspension.
11. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Lubricant Replacement - Front Drive Axle .
12. Lower the vehicle.
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Old 02-03-2009, 04:32 PM   #10
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Default Re: Complete disassembly and reassembly of a IFS front assembly.

Clutch Fork Replacement - Front Drive Axle
Removal Procedure


Object Number: 890589 Size: SH
Click here for detailed picture of above image.
1. Remove the inner axle shaft and housing assembly. Refer to Inner Shaft and/or Housing Replacement - Front Drive Axle .
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.

Installation Procedure


Object Number: 890589 Size: SH
Click here for detailed picture of above image.
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
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