Front Axle Center Disconnect

Front Axle Center Disconnect






Disassembly






1. NOTE: Draining of the axle is not necessary unless the entire carrier is to be disassembled.

If carrier has not been drained of lubricant, make sure that Axle Service Plugs T95T-4850-A are in place. If so, use Bench Mounted Holding Fixture T57T-500-B to shift axle so that the axle tube is pointing upward.






2. Remove Axle Service Plug T95T-4850-A2.

3. Remove center disconnect shift motor cover.

4. Inspect pads on the shift fork for wear or damage.

5. NOTE: Other than damage to the shift fork or shift motor, disassembly of the shift motor assembly is not necessary.

NOTE: Note the configuration of the shift fork and its location in respect to the locking collar before removing it as it must be reinstalled the same way.

There are three snap rings that must be removed from the shift motor shaft in order to disassemble the shift motor assembly. Two of the snap rings are on the shaft proper and hold the shift fork to the shaft. The other snap ring is on the base of the shaft and holds the shift motor inside the housing. Inspect these snap rings for damage or wear. There is also on O-ring on the base of the shaft which should also be inspected. The cover is sealed with a gasket which also requires inspection.

6. Make sure that the locking collar inside the center disconnect housing is free to slide from side to side.

7. NOTE: There are two thrust washers held in by a large C-clip against the outboard side of the disconnect housing.

Remove C-clip from inside the center disconnect housing and remove the outer axle shaft by pulling it from the axle tube. This will free up the thrust washers and locking collar.

8. Remove the locking collar and thrust washers from the center disconnect housing and inspect them for wear or damage.






9. Examine the outer axle shaft splines for wear or damage. Check outer axle shaft pocket bushing for damage. If bushing is worn or damaged, remove bushing using Blind Hole Puller D80L-100-N or equivalent and Impact Slide Hammer T50T-100-A, and replace bushing using Blind Hole Puller D80L-100-N or equivalent.

10. Slide the inner axle shaft out through the axle tube. Inspect the shaft bearing surface and splines for wear or damage.






11. Remove axle shaft oil seal using Converter Seal Remover T94P-77001-BH along with Impact Slide Hammer T50T-100-A.






12. Remove the outer axle shaft needle bearing using Bearing Remover T94P-77001-KH along with Impact Slide Hammer D79P-100-A or equivalent.






13. Remove inner axle shaft synthetic bushing using Bearing Remover T94P-77001-KH along with Impact Slide Hammer D79P-100-A or equivalent.

Assembly






1. Install seal in left corner bore using Axle Seal Replacer T95T-3010-A along with Driver Handle T80T-4000-W.

2. Shift Bench Mounted Holding Fixture T57T-500-B 180� so that right-side axle tube is pointing up.






3. Install new inner axle shaft synthetic bushing using Bushing Replacer T95T-1175-C along with Driver Handle T80T-4000-W.

4. Install inner axle shaft.






5. Install new outer axle shaft needle bearing using Axle Bearing Replacer T95T-1175-B along with Driver Handle T80T-4000-W.

6. Install locking collar and thrust washers inside center disconnect housing.

7. Install outer shaft with pocket bearing end first. Drop the outer shaft through the synthetic thrust washer and the steel protective thrust washer respectively. The synthetic thrust washer should go flush against the outboard bore of the center disconnect, and the steel thrust washer should go flush against the synthetic thrust washer. The stud on the end of the inner axle shaft should mount into the pocket bushing of the outer axle shaft. The large snap ring fits in a groove on the shaft and holds the thrust washers in place.






8. Install the axle shaft oil seal using Axle Seal Replacer T95T-3010-A and Driver Handle T80T-4000-W.

9. NOTE: Steps 11 and 12 need only be performed if the shift motor was disassembled.

NOTE: Make sure that shift fork is installed with the same configuration it was before disassembly.

Install new O-ring on base of shift motor shaft and insert shaft into shift motor cover and through the shift fork.

10. Install snap ring at base of shift motor shaft in order to secure shift motor to cover and install snap rings to grooves in shift motor shaft to secure the shift fork to the shaft.

11. Install new gasket on center disconnect cover mounting surface and install shift motor cover. Make sure that the locking collar and shift fork are configured in relation to one another the same way they were before disassembly. Tighten mounting screws to 9.5-12.2 Nm (84-108 lb-in).






12. Add 148ml (5 oz.) of API Grade GL5 hypoid gear lubricant to the shift motor housing. Add lubricant through the housing plug hole.