Front Differential

FRONT DRIVE AXLE ASSEMBLY AND ASSOCIATED PARTS

REMOVAL
1. Jack up the vehicle and support it using jack stands.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper.
5. Remove the antilock brake system speed sensor.
6. Remove the hub and disc assembly, refer to Wheel Hub; Service and Repair.
7. Remove propeller shaft, refer to Drive/Propeller Shaft; Service and Repair.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
9. Remove suspension crossmember.





10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.





13. Disconnect the hose of the shift on the fly, at the hose clip portion (1).
14. Disconnect the shift switch connector (2).
15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame.





16. Disconnect between the right side upper control arm and the knuckle, then remove the knuckle with lower control arm.

CAUTION: When removing the knuckle, be careful not to damage the oil seal inside of the knuckle.

17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the jack slowly. Remove the left side drive shaft end from the knuckle, then lower the axle assembly from the vehicle.

CAUTION:
1. During the work, be sure that the axle assembly is supported securely.
2. Be careful not to damage the bellows of the power steering unit by interference.
3. Be careful not to damage the hose bracket of the shift on the fly interference.

INSTALLATION
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side drive shaft to the knuckle, then install the mount bolts and nuts.

CAUTION:
1. Be careful not to damage the bellows of the power steering unit by interference.
2. Be careful not to damage the hose bracket of the shift on the fly interference.
3. When installing the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle.





3. Tighten the mounting bolts and nuts to the specified torque.
Torque: 168 Nm (124 ft. lbs.)
4. Install the right side knuckle with lower control arm to the upper control arm.

CAUTION: When insert the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts and nuts.

NOTE: Adjust the buffer clearance before tighten the bolts and nuts of the lower control arm.





6. Install the hose of the shift on the fly (1).
7. Install the shift switch connector (2) of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque.
Torque: 118 Nm (87 ft. lbs.)
9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque.
Torque: 93 Nm (69 ft. lbs.)
10. Install lower nuts of the stabilizer link, tighten it to the specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
13. Install the front propeller shaft.
14. Install the hub and disc assembly and adjust the bearing preload.
15. Install the wheel sensor of the antilock brake system.
16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque.
Torque: 50 Nm (37 ft. lbs.)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
20. Tighten the bolts and nuts of the lower control arm to the specified torque.