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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 30 (FRONT DRIVE AXLE)REPAIR INSTRUCTIONSINNER AXLE SHAFT SHIM ADJUSTMENTNOTES
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Inner Axle Shaft Shim Adjustment: Notes

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Notes
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Tools Required

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:

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)
  1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Inner Axle Seal and/or Bearing Replacement - Front Drive Axle .
    2. Fig 1: Front Drive Axle Components (9.25 Inch)
    GM694347Courtesy of GENERAL MOTORS CORP.
  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.
    4. 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.
    5. Fig 2: Using J 34672 To Measure Inner Axle Shaft Distance
    GM1656422Courtesy of GENERAL MOTORS CORP.
  5. Install the J 34673  (1) and the J 34672  (2) onto the inner shaft housing as shown. See Special Tools .
  6. Using the J 34672  , measure the distance from the edge of the inner axle shaft to the surface of the J 34673  . See Special Tools . Ensure the base of the J 34672  is flat against the inner axle shaft. See Special Tools .
    7. Fig 3: Measuring Differential Carrier Housing Machined Surface To Front Drive Axle Clutch Shaft Outer Surface
    GM674843Courtesy of GENERAL MOTORS CORP.
  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. See Special Tools .
  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  . See Special Tools .

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

    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.
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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.