Front

Front Drive Axle Assembly








Removal
1. Jack up the vehicle and support it using a jack stand.
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.
7. Remove the propeller shaft.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
9. Remove the 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.
14. Disconnect the actuator connector.
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 at 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. Make sure the axle assembly is supported securely when performing the repairs.
2. Do not damage the power steering unit when performing the repairs.
3. Do not damage the shift-on-the fly hose bracket when performing the repairs.

Installation
1. Support the differential case with a 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. Do not damage the power steering unit when performing the repairs.
2. Do not damage the shift-on-the fly hose bracket when performing the repairs.
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: Carefully insert the drive shaft into the knuckle, to avoid damaging the oil seal.

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

Note: Adjust the buffer clearance before tightening the bolts and nuts of the lower control arm.

6. Install the hose of the shift on the fly.
7. Install the actuator connector 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 speed 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.