Attachment III - Technical Information
OVERVIEWSome of the affected vehicles may be assembled with missing or incorrect front axle mounting bolt(s). The following instruction provides the details for identifying and replacing incorrect or missing mounting bolts.
INSPECTION
1. Raise the vehicle on a hoist.
2. Inspect the three front axle mounting bolts. The vertical mounting bolt has a large washer; the right and left horizontal mounting bolts do not have a washer. See Figure 1.
^ If the correct bolts have been installed, no repair is required. Lower and release the vehicle.
^ If the incorrect bolt(s) have been installed in any of the three locations, the incorrect bolt(s) must be replaced with the correct (new) bolt and a new nut. Go to Mounting Bolt Replacement.
^ If any bolt(s) is missing, follow the steps in Inspection and Installation for Missing Mounting Bolts.
MOUNTING BOLT REPLACEMENT
NOTE:
If more than one incorrect bolt was identified, replace them one at a time.
1. Position a jackstand under the front axle, below the mount with the incorrect bolt.
2. Remove and discard the incorrect bolt and nut.
3. Install the correct (new) bolt (vertical bolt N81 1242-S426; horizontal bolt N808403-S426) and a new nut (N811623-S426). Tighten to 70 Nm (52 lb-ft).
4. Remove the jackstand and repeat steps 1-3 as necessary.
5. Lower and release the vehicle.
INSPECTION AND INSTALLATION FOR MISSING MOUNTING BOLTS
NOTE:
Perform this procedure only if the vehicle is missing a mounting bolt(s). If more than one mounting bolt is missing, install them one at a time.
MOUNTING BOLT REPLACEMENT
NOTE:
If more than one incorrect bolt was identified, replace them one at a time.
1. Position a jackstand under the front axle, below the mount with the incorrect bolt.
2. Remove and discard the incorrect bolt and nut.
3. Install the correct (new) bolt (vertical bolt N811242-S426; horizontal bolt N808403-S426) and a new nut (N811623-S426). Tighten to 70 Nm (52 lb-ft).
4. Remove the jackstand and repeat steps 1-3 as necessary.
5. Lower and release the vehicle.
INSPECTION AND INSTALLATION FOR MISSING MOUNTING BOLTS
NOTE:
Perform this procedure only if the vehicle is missing a mounting bolt(s). If more than one mounting bolt is missing, install them one at a time.
1. Inspect the horizontal mounting bushings and constant velocity joint boots for tears or missing chunks. Inspect the axle halfshaft for signs of damage. Also, inspect the area of the torsion bar as indicated in the illustration for missing paint or nicks from contact with the halfshaft. See Figure 2.
^ If any damage is found, contact the Special Service Support Center at 1-800-325-5621 for further instruction.
^ If damage is not found, go to step 2.
2. Position an adjustable jackstand under the front axle below the mount with the missing bolt.
3. Raise the axle up until the center of the bushing is aligned with the hole in the frame.
4. Install the correct (new) bolt (vertical bolt N811242-S426; horizontal bolt N808403-S426) and new nut (N811623-S426). Tighten to 70 Nm (52 lb-ft).
5. Remove the jackstand, and repeat steps 2-4 as necessary.
6. Lower the vehicle.
7. Test drive the vehicle in 4x2 and 4x4 mode.
^ If any abnormal noise is heard coming from the front axle or halfshafts, contact the Special Service Support Center at 1-800-325-5621 for further instruction.
^ If abnormal noise is not present, release the vehicle to the owner.