Intermediate Shaft Bearing Assembly Assemble (A4WD)

Intermediate Shaft Bearing Assembly Assemble (A4WD)

Tools Required
* J 45225 Axle Seal Installer
* J 45232 Differential Bearing Adjuster Needle Bearing Replacer - LH
* J 45359 Axle Seal Installer
* J 8092 Universal Driver Handle- 3/4 in - 10

Assembly Procedure

1. Install the inner shaft bearing, print side out, into the intermediate shaft bearing inner case half using the J 45232 (2) and the J 8092 (1).

2. Install the inner shaft bearing, print side out, into the intermediate shaft bearing outer case half using the J 45232 (2) and the J 8092 (1).

3. Install the inner shaft bearing (print side out) into the intermediate shaft bearing outer case half using the J 45232 (2) and the J 8092 (1).

4. Install the thrust washer.

5. Install the clutch fork sleeve.

6. Install the thrust washer to the outer intermediate shaft bearing case half.
Use grease to hold the thrust washer in place.
7. Apply a bead of sealant, GM P/N 1052942 or equivalent, to the sealing surface of one side of the intermediate shaft bearing housing case.
8. Install the outer intermediate shaft bearing housing case to the inner intermediate shaft bearing housing case.

Notice: Refer to Fastener Notice .

9. Install the intermediate shaft bearing case bolts.

Tighten the intermediate shaft bearing case bolts to 48 N.m (35 lb ft).

10. Install the new inboard, oil pan side, seal on top of the seal bore.

11. Install the new seal using the J 45225 (2) and the J 8092 (1).

Notice: The outboard intermediate shaft bearing assembly seal must be installed 0.9-1.1 mm (0.035-0.043 in) below the surface of the intermediate shaft bearing assembly housing bore. If the seal is not installed properly, damage to the seal may occur.

12. Install the new seal using the J 45359 (2) and the J 8092 (1).

13. Pack the cavity of the inner intermediate shaft bearing housing with 55-65 cc (1.86-2.20 oz) of grease, GM P/N 12377985 or equivalent.
14. Install the intermediate shaft bearing plug.