Inner Axle Shaft Shim Adjustment: Notes

Tools Required

• J 34672 Depth Micrometer
• J 34673 Flat Gauge Bar
• J 8001 Dial Indicator Set

The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced:

• The inner axle shaft
• The inner axle shaft housing
• The clutch shaft
• The differential carrier case
• The ring and pinion gears
• The differential assembly
• The differential bearings
• The carrier connector

Front drive axle clutch shims are available in the following sizes:

8.25 Inch Axle	9.25 Inch Axle
1.27 mm (0.05 in)	1.30 mm (0.05 in)
1.52 mm (0.06 in)	1.52 mm (0.06 in)
1.78 mm (0.07 in)	1.80 mm (0.07 in)
2.03 mm (0.08 in)	2.03 mm (0.08 in)
2.29 mm (0.09 in)	2.30 mm (0.09 in)
2.54 mm (0.10 in)	2.54 mm (0.10 in)
2.70 mm (0.11 in)	2.80 mm (0.11 in)
3.05 mm (0.12 in)	3.05 mm (0.12 in)
3.30 mm (0.13 in)	3.30 mm (0.13 in)
3.56 mm (0.14 in)	3.55 mm (0.14 in)
3.81 mm (0.15 in)	3.80 mm (0.15 in)
-	4.05 mm (0.16 in)
-	4.30 mm (0.17 in)
-	4.55 mm (0.18 in)
-	4.80 mm (0.19 in)

1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement .
Fig 1: Front Drive Axle Components (9.25 Inch)
Courtesy of GENERAL MOTORS COMPANY
2. Install the following components into the inner axle shaft housing:
   1. Install the inner axle shaft (1) into the inner axle shaft housing (4).
   2. Install the thrust washer (with tabs) (5).

      Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.

   3. Install the thrust washer (without tabs) (6).
   4. Install the retaining ring (7) into the inner axle shaft (1).
3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
IMPORTANT:

In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.

4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.
Fig 2: Measuring Inner Axle Shaft Distance
Courtesy of GENERAL MOTORS COMPANY
5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown.
6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft.
Fig 3: Measuring Differential Carrier Housing Machined Surface To Front Drive Axle Clutch Shaft Outer Surface
Courtesy of GENERAL MOTORS COMPANY
7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7.

   This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 .

9. Using a micrometer, measure the thickness of the J 34673 .
10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8.

    This is the shim thickness for the front axle without having any axle shaft endplay.

11. The correct shim size will be one size smaller than the figure obtained in the previous step.

    Note the following examples:

    • If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim.
    • If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.