Front Drive Axle

Differential Carrier Assembly Replacement (4.2L In-Line Six Cylinder)

Removal Procedure




1. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation.




2. Remove the engine protection shield. Refer to Engine Protection Shield Replacement.
3. Drain the engine of oil.
4. Drain the front drive axle. Refer to Front Axle Lubricant Replacement.
5. Remove the front propeller shaft from the front axle. Refer to Front Propeller Shaft Replacement.
6. Wrap the bearing caps with tape in order to prevent the loss of the roller bearings.




7. Remove the antilock brake system (ABS) wiring harness from the retainers.




8. Remove the brake hose retaining bolts.
9. Remove the front drive axle vent hose.




10. Remove the left and right upper ball pinch bolt and nut.




11. Remove the left and right upper shock module retaining nuts.




12. Remove the front stabilizer bar links from the frame. Refer to Stabilizer Shaft Link Replacement.
13. Remove the shock module from the frame.
14. Remove the steering knuckle from the upper control arm.
15. Remove the left and right front wheel drive shafts from the front drive axle.




16. Relocate and secure the left and right front wheel drive shafts to the frame.




17. Using mechanics wire or hook, support the front shock modules and steering knuckle.




18. Remove the power steering gear assembly. Refer to Power Steering Gear Replacement.




19. Remove the inner shaft (2) from the front drive axle. Refer to Front Drive Axle Inner Shaft Replacement.




20. Remove the front drive axle from the oil pan.
21. Secure the front drive axle to the frame.
22. Remove the oil pan. Refer to Oil Pan Replacement.




23. Remove the front drive axle from the vehicle.

Installation Procedure




1. Install the front drive axle to the frame.
2. Secure the front drive axle to the frame.
3. Install the oil pan. Refer to Oil Pan Replacement.
4. Remove the front drive axle from the frame.
5. Install the front drive axle to the oil pan.

Notice: Refer to Fastener Notice.

6. Install the front drive axle mounting bolts.

Tighten the front drive axle mounting bolts to 85 N.m (63 lb ft).




7. Install the inner axle (2) to the front drive axle. Refer to Front Drive Axle Inner Shaft Replacement.




8. Install the power steering gear. Refer to Power Steering Gear Replacement.
9. Remove the left and right front wheel drive shafts from the frame.
10. Remove the left and right shock module and steering knuckles from their supports.
11. Install the right and left front wheel drive shafts to the front drive axle.
12. Install the vent hose to the front drive axle.
13. Install the left and right shock modules to the frame.
14. Install the upper shock module retaining nuts.

Tighten the upper shock module mounting bolts to 100 N.m (74 lb ft).

15. Install the steering knuckle to the upper control arm.
16. Install the upper ball joint pinch bolt and nut.

Tighten the upper shock module mounting bolts to 40 N.m (30 lb ft).




17. Install the front stabilizer bar links to the frame. Refer to Stabilizer Shaft Link Replacement.




18. Install the brake hose retaining bolts.

Tighten the brake hose retaining bolt to 25 N.m (18 lb ft).




19. Install the right and left ABS wiring harness in the retainers.
20. Install the front propeller shaft from the front axle. Refer to Front Propeller Shaft Replacement.
21. Fill the front drive axle with the proper fluid. Refer to Front Axle Lubricant Replacement.
22. Fill the engine with the proper amount motor oil. Refer to Approximate Fluid Capacities.




23. Install the engine protection shield. Refer to Engine Protection Shield Replacement.




24. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation.