Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement

Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement Front Drive Axle.
3. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) Wheel Drive Shaft Replacement (2500)Wheel Drive Shaft Replacement (1500) Wheel Drive Shaft Replacement (1500).





Note: 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 10.

4. Using a hammer and brass drift, disconnect the inner axle shaft from the differential case side gear.




5. Remove the inner axle shaft housing nuts from the bracket.




6. Remove the inner axle shaft housing bolts (2) from the differential carrier assembly.
7. Remove the inner axle shaft (1) and inner axle shaft housing (4) from the vehicle.
8. Remove the inner axle shaft housing gasket (3) from the inner axle shaft housing (4).
9. Remove the inner axle shaft seal and the bearing from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle) Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle).




10. Using a hammer and a brass drift, remove the inner axle shaft.

Installation Procedure

Note: Align the splines on the inner axle shaft with those of the differential side gear before installing the inner axle shafts.





Note: Ensure that the inner axle shaft is properly retained in the differential

1. Using a soft-faced mallet, install the inner axle shaft.
2. Install the right side NEW inner axle shaft bearing and the new seal to the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle) Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle).





Note: Do not install the inner axle shaft completely into the inner axle shaft housing at this time.

3. Install the inner axle shaft (1) into the inner axle shaft housing (4).
4. Install the NEW inner axle shaft housing gasket (3).
5. Install the inner axle shaft (1) and the inner axle shaft housing (4) to the differential carrier assembly.
6. Install the inner axle shaft housing bolts (2) and tighten to 40 Nm (30 lb ft).




7. Install the inner axle shaft housing nuts to the bracket and tighten to 100 Nm (75 lb ft).

Note: Ensure that the inner axle shaft is properly retained in the differential.

8. Using a soft-faced mallet, install the inner axle shaft.




9. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) Wheel Drive Shaft Replacement (2500)Wheel Drive Shaft Replacement (1500) Wheel Drive Shaft Replacement (1500).
10. Using the correct fluid, fill the differential carrier assembly with axle lubricant. Refer to Front Axle Lubricant Replacement Front Drive Axle.
11. Lower the vehicle.