Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 417 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSINNER AXLE SHAFT SHIM ADJUSTMENTNOTES

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Inner Axle Shaft Shim Adjustment: Notes

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Notes

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Tools Required

J 34672 Depth Micrometer. See Special Tools and Equipment .
J 8001 Dial Indicator Set. See Special Tools and Equipment .

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 output shaft
The differential carrier case
The ring and pinion gears
The differential case assembly
The differential bearings
The carrier connector

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

Inner Axle Shaft Shim Adjustment

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)

Install the inner axle bearing and the inner axle seal, if necessary. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .
Install the following components into the inner axle shaft housing, 8.25 inch axle:
1. Install the inner axle shaft (1) into the front drive axle housing (4).
2. Install the thrust washer (5).
3. Install the retaining ring (7) into the front drive axle clutch gear (6).
4. Install the front drive axle clutch gear (6) onto the inner axle shaft (1).
  Drive the front drive axle clutch gear (6) into place with a plastic hammer.
Install the following components into the inner axle shaft housing, 9.25 inch axle:
1. Install the inner axle shaft (1) into the front drive axle housing (4).
2. Install the thrust washers (5, 6).
3. Install the retaining ring (7) into the inner axle shaft (1).

Fig 2: Front Drive Axle Components (9.25 Inch)

Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.