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Home >> Chevy Truck >> 1995 >> K 2500 Suburban 4WD V8-6.5L DSL Turbo VIN F >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Front Drive Axle >> Drive Axle Replacement >> Models Over 8600 GVW

Models Over 8600 GVW

FRONT DRIVE AXLE






Remove or Disconnect

Tools Required:
- J 28733-B Axle Remover
- J 24319-B Steering Linkage Puffer
- J 8059 Snap Ring Pliers
- J 35910 Seal Clamp Tool
- J 36605 Front Knuckle Seal Installer

- Raise vehicle and support it with safety stands.

1. Wheel and tire assembly




- Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes to prevent drive axle from turning.





2. Drive axle hub nut (203) and washer (202).
- Loosen but do not remove at this time 6 bolts (200) securing inboard CV joint drive flange to the output shaft companion flange.

Important
- Be careful when removing inner boot to avoid damaging it.





3. Brake pipe support bracket from upper control arm to allow extra travel of knuckle.
4. Cotter pin and nut from outer tie rod.





5. Separate the outer tie rod ball stud from the steering knuckle using J 24319-B.

NOTICE: Do not attempt to disengage the joint by driving a wedge-type tool between the joint and the knuckle This may cause seal damage.

- Push linkage to opposite side of the vehicle and secure outer tie rod up and out of the way. This will provide the needed clearance to remove the drive axle.





6. Lower shock mounting nut and bolt.
- Collapse the shock absorber and secure if necessary.





7. Stabilizer shaft components as follows:
- Remove stabilizer shaft bushing and bracket.
- Remove stabilizer shaft bolt, spacer, and bushings at the lower control arm.
- This is required on K2 vehicles with C6P option. (8600 lb GVW rating. Refer to option listing for vehicle). It Is also required on K3 vehicles to provide needed clearance for drive axle removal.
8. Position floor stand behind the steering knuckle.

CAUTION: The floor jack or stand must remain under the control arm while servicing the drive axle to maintain spring and control arm position. Failure to do so could result in personal injury.

9. Disconnect the cotter pin (138) from the upper control arm ball joint stud.
- Loosen (do not remove at this time) the stud nut on the upper ball joint stud.
- Loosen the stud from the knuckle.





10. Remove nut (139).
11. Stud (137) from knuckle.
12. Nut.

Important
- Cover the shock mounting bracket and the ball stud on the lower control arm with a shop towel to prevent possible drive axle seal damage during removal and installation.





13. Knuckle assembly using J 28733-B (or equivalent) and separate outer CV joint splined shank from knuckle hub.
14. Six bolts from inboard joint flange.
- Support inboard end of drive axle. Move knuckle and hub assembly outward to free splined shank from hub.
15. Drive axle from vehicle.

Important
- Wipe the wheel bearing seal area on the knuckle clean.
- Check the seal for cuts or tears.

16. Lubricate the seal lip.
- If seal is cut or torn, inspect the wheel bearing for damage and replace the seal.
17. Replace the seal as follows:
- Pry old seal from knuckle and discard.
- Lubricate the new seal lip.
- Use J 36605 to install the seal in the knuckle.

Install or Connect

- Prior to drive axle installation, cover the shock mounting bracket, lower control arm ball stud, and all other sharp edges with shop towels so that drive axle seal is not damaged during assembly.

Important
- Lubricate the drive axle splines and knuckle with an approved high temperature wheel bearing grease.

1. Insert outer CV joint splined shank into knuckle hub and secure inboard CV joint flange to companion flange with bolts. Do not Tighten.
2. Upper ball joint to the steering knuckle.
3. Stud nut.

Tighten
- Stud nut to 83 Nm (61 lb ft).

4. Cotter pin.
- Lubricate the upper ball joint until grease appears at the seal.
5. Stabilizer shaft bushing (65) and bracket (64).

Tighten
- Clamp to 33 Nm (24 lb ft).

6. Stabilizer shaft bolt (62), spacer (56), and bushings (65).
- Remove floor jack or stand from beneath lower control arm.
7. Shock absorber to the lower shock mounting bracket.
8. Shock mounting bolt (190), washer (191), and nut (192).

Tighten
- Nut to 73 Nm (54 lb ft).

9. Outer tie rod to steering knuckle.
10. Outer tie rod nut.

Tighten
- Nut to 47 Nm (35 lb ft).

Important
- Advance the nut to align the nut slot with the cotter pin hole. Never back the nut oft to align the cotter pin hole.

11. Install new cotter pin and spread the ends to secure.
12. Brake pipe support bracket to the upper control arm.

Tighten
- Nut to 17 Nm (13 lb ft).

Important
- Make sure that the brake hose is not twisted or kinked, or damage to the hose could result.

13. Hub nut washer (202) and nut (203). Seat shank splines in hub.
14. Insert a drift through brake caliper to prevent drive axle from turning.

Tighten
- Inboard flange bolts to 80 Nm (60 lb ft).

15. Hub nut.

Tighten
- Hub nut to 245 Nm (180 lb ft).

16. Remove drift, install wheels, remove safety stands, and lower the vehicle.

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