Removal

Oil Pan

Special Tools:

Removal

All Vehicles

1. Disconnect battery ground cable. Refer to Service and Repair

2. Raise and support the vehicle. Refer to Description and Operation

3. Remove the nuts.






CAUTION: Do not allow the transmission to hang freely.

4. Position the High-Lift Transmission Jack under the transmission.
- Life the transmission.






5. Remove the crossmember.
- Remove the six bolts.
- Remove the crossmember.






6. Remove the support insulator bracket.






7. Remove the transfer case skid plate, if equipped.






8. Disconnect the heated oxygen sensors (HO2S).






NOTE: The RH side is shown, the LH side is similar.

9. Remove the three-way catalytic converters (TWC).






10. Install the crossmember.
- Position the crossmember.
- Install the six bolts.






11. Lower the transmission onto the crossmember and position the High-Lift Transmission Jack aside.

NOTE: Place a suitable container under the oil pan.

12. Drain the engine oil and reinstall the drain plug.






13. Remove the nut and position the bracket aside.






14. Lower the vehicle.

NOTE: Steering column must remain in the unlocked position.

15. Place the front wheels in the straight-ahead position.

16. Raise and support the vehicle.

17. Disconnect the power steering return hose at the power steering fluid cooler.
- Allow the system to drain.






18. Remove the power steering fluid cooler-to-crossmember nuts.






19. Disconnect the power steering return hose. Remove the power steering fluid cooler.






CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings.
NOTE: To avoid damage or scratching to the center cap, place face up when removed.

20. Remove the front wheel and tire assemblies.
- If necessary, remove the center cap.
- Remove the nuts, and the wheel and tire assemblies.






21. Remove the inner fender splash shields.

22. Remove the top motor mount nuts.






23. Remove the bolts and the radiator air deflector.






NOTE: LH tie-rod end shown, RH similar.

24. Loosen the tie-rod end jam nuts.






25. Disconnect the tie-rod ends.
- Remove and discard the cotter pins.
- Remove the castellated nuts.
- Separate the tie-rod ends from the steering knuckles. Do not damage the tie-rod end seals.






26. Remove the LH tie-rod end.
- Count and record the number of turns required to remove the LH tie-rod end.






27. Remove the front stabilizer bar.
- Mark the driver side end of the stabilizer bar for correct installation.

28. Disconnect the steering gear hoses.
- Disconnect the power steering pressure hose.
- Disconnect the power steering return hose.






29. Plug the ends of all fluid hoses removed and ports in the steering gear to prevent damage and entry of dirt.

30. Rotate the steering column shaft to access the intermediate shaft pinch bolt. Remove the pinch bolt.






31. Lower the vehicle.

32. Turn the steering wheel back to the straight-ahead position. Turn the ignition key to the locked position.

33. Raise and support the vehicle.

CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected, or damage to the air bag sliding contact will result.

34. Disconnect the intermediate shaft from the steering gear input shaft.

35. Raise the engine.
- Position a block of wood between a screw jack and the bottom of the oil pan to avoid damaging the oil pan while raising the engine.






CAUTION: Hold the tops of the steering gear-to-crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
36. Remove the nuts.






37. Remove the stud bolts and washers.






38. Remove the steering gear-to-crossmember insulator bushings.






39. Turn the steering gear input shaft to the right until the stop is reached.






40. Move the steering gear as far to the RH side of the vehicle as possible.

41. Move the LH front wheel spindle tie-rod forward to clear the crossmember. Turn the steering gear input shaft to the left until the stop is reached.






42. Remove the steering gear from the vehicle.






4X4 VEHICLES

CAUTION: Do not allow the calipers to hang by the hoses.
NOTE: Remove or tape the brake pads to prevent them from falling out of the caliper guides.
NOTE: Install a wheel nut to secure each brake disc in place.

43. Remove the bolts and position both calipers aside.






44. Unclip the left and right wheel anti-lock sensor wiring harnesses from the locators on the vehicle chassis, located above the stabilizer bar brackets.


CAUTION: Do not allow the halfshafts to hang freely. It is possible to overextend and internally separate the inner CV joint.
CAUTION: Take necessary precautions to protect the machined sealing surfaces on each axle.

45. Remove both pinch bolts and disconnect the upper ball joints.
- Pull the RH halfshaft, with the wheel knuckle, away from the front axle until the halfshaft is out of the front axle.
- Pull the LH halfshaft, with the wheel knuckle, away from the front axle. The LH halfshaft cannot be removed from the front axle at this time.






NOTE: Tape the U-joint bearing caps to prevent them from falling off the U-joint.
NOTE: Index-mark the front axle pinion flange to the front driveshaft.

46. Remove and discard the bolts and straps. Secure the driveshaft out of the way.

NOTE: Use the Axle Service Plugs Set T95T-4850-A to plug the axle openings.






47. Secure the axle housing to a suitable lift.






48. Remove and discard the bolts.






49. Remove the top front axle housing bolt, then lower the axle 25 mm (1 inch) and move to the right 18 mm (0.75 inch), guiding the LH axle halfshaft out of the axle.






50. Disconnect the vent hose from the front axle housing.






51. Lower the axle from the vehicle.

ALL VEHICLES

52. Remove the oil filter assembly.






53. Position aside the oil bypass assembly.
- Remove the bolt and the O-ring seal.






NOTE: Remove the oil pump and the oil pan as an assembly.
54. Remove the bolts and lower the oil pan.






55. Remove the bolts, lower the oil pump into the oil pan, and remove the oil pan.