Axle Assembly

Axle Assembly-Front





Special Tool(s)

Removal and Installation
1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove front wheel and tire assemblies.





3. WARNING: Remove the brake pads, or tape them to the anchor plate, to prevent them from falling out of the anchor plate.

CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose.

NOTE: Install a wheel nut to secure the brake disc in place.

Remove the bolts and position the front disc brake calipers aside.





4. Remove the cotter pin and the nut from each tie-rod end.





5. CAUTION: Do not damage the tie-rod dust boot when installing the special tool.

NOTE: Remove the adapter from the ball end of the special tool. Apply a small amount of grease to the tie-rod stud and to the ball of the special tool.

Using the special tool, separate the outer tie-rod ends from the knuckles.





6. Unclip the anti-lock sensor wiring harnesses from the locators.





7. Remove the bolts retaining the anti-lock sensor wiring harnesses to the knuckles.





8. NOTE: Using a suitable jack stand, support the front suspension lower arm.

Remove the nuts and disconnect the RH shock absorber from the front suspension lower arm.





9. CAUTION: Do not allow the knuckle to hang freely. It is possible to overextend and internally separate the inner CV joint from its housing.

Remove the pinch bolts and disconnect the upper ball joints from the knuckles.





10. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

NOTE: The LH inboard CV joint housing ;: ill not separate completely from the axle at this time

NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.

Using the special tool, disengage the LH inboard CV joint housing from the differential side gear.





11. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

NOTE: A circlip retains the inboard CV joint housing to the axle shaft in the axle tube.

Using the special tool, disengage the RH inboard CV joint housing from the axle tube.





12. CAUTION: Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing, or the axle shaft splines.

CAUTION: Install a new retainer circlip on the outboard splined end of the axle shaft before reseating the axle shaft in the differential side gear.

Pull the knuckle, the halfshaft, and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft.





13. Using the special tool, plug the axle tube.

14. CAUTION: Index-mark the front axle pinion Range and the front driveshaft, and the front output shaft and the front driveshaft constant velocity joint.

CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.

CAUTION: Tape the bearing cups to prevent them from falling off the spider.

Remove the front driveshaft.





15. Secure the differential housing to a suitable lift.








16. NOTE: The front axle-to-frame bolt will have two different tightening specifications, based upon the type of frame coating used.

NOTE: The washer must be placed between the bracket and frame attachment.

Remove and discard the bolts.
^ For vehicles with a non-wax (black) coated frame, tighten the bolt to 130 Nm (76 ft. lbs.).
^ For vehicles with a wax (grey) coated frame, tighten the bolts to 90 Nm (66 ft. lbs.).
17. Lower the axle approximately 25 mm (I inch). Guide the LH halfshaft out of the axle while moving the axle approximately 25 mm (1 inch) to the RH (passenger) side of the vehicle.





18. Disconnect the vent hose from the differential housing vent tube.
19. Lower the axle from the vehicle.

20. CAUTION: Make sure the spacer between the pinion arm bushing and frame is installed in the same position as when removed.

CAUTION: Install a new retainer circlip on the left inboard CV joint housing and on the right-hand axle shaft.

CAUTION: Check the retainer circlip engagement after installing the RH axle shaft and each halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.

CAUTION: Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If new bolts are not available, coat the threads of the original bolts with threadlock.

NOTE: The axle-to-frame bolts will have two different tightening specifications. based upon the type of frame coating used. The two types are
^ a non-wax coated or E-coated frame, which is black and very smooth
^ a wax coated frame, which is gray and very sticky

To install, reverse the removal procedure
^ Check and, if necessary, fill the axle with lubricant to 9 56 mm (0.38 inch) below the bottom of the axle fill hole