4 Wheel Drive
REMOVAL1. Raise and support vehicle and remove front wheel.
2. Set control handle to FREE position and remove freewheel hub attaching bolts and the hub. Do not hammer the freewheel hub.
3. Remove caliper assembly, leaving brake hose attached, and suspend out of way.
4. Remove snap ring and spacer, then the set bolts and bearing set plate.
5. Using suitable tool, remove bearing locknut.
6. Remove hub and plate assembly, being careful that washer and bearing do not fall, then the dust cover.
7. Remove tie rod end nut, then, using tool 490118850C or equivalent, separate tie rod end from knuckle. If removal is difficult, lightly tap ball joint coupling of knuckle with hammer.
8. Disconnect the stabilizer and lower side of shock absorber mounting.
9. Support lower arm with suitable jack and remove lower arm ball joint nut, then, using tool 490727575 or equivalent, separate knuckle from lower arm.
10. Remove upper arm ball joint nut and, using tool 490727575 or equivalent, separate knuckle from upper arm.
11. Lower the lower arm and remove knuckle.
DISASSEMBLY
1. Remove Knuckle oil seal and take out bearing inner race.
2. Using suitable bar, lightly tap out bearing outer race.
3. Using suitable puller, remove needle bearing from knuckle.
4. Scribe alignment marks on disc plate and hub, then remove bolts and separate disc plate and hub.
5. Remove hub oil seal and drive out bearing inner race.
6. Using suitable bar, remove bearing outer race by tapping lightly.
ASSEMBLY
1. Using suitable tool, press needle bearing into knuckle.
2. Install inner bearing in hub, then press in oil seal with suitable tools and apply suitable grease to oil seal lip.
3. Using suitable tool, press fit outer side bearing outer race.
4. Using suitable tool, press fit inner side bearing outer race.
5. Using suitable tool, press fit oil seal until it is flush with hub end surface, then apply suitable grease to oil seal lip.
6. Align match marks on wheel hub and disc plate and torque attaching bolts to specification.
7. Apply suitable grease to inside of hub and install outer bearing and race.
INSTALLATION
1. Insert front axle driveshaft into knuckle and install lower arm ball joint nut, tightening by hand.
2. Jack up lower arm so that upper arm ball joint is connected to knuckle.
3. Torque upper arm ball joint nut and lower arm ball joint nut to specification, then install new cotter pins.
4. Torque tie rod end to knuckle arm nut to specification and install new cotter pin.
5. Install dust cover, torquing to specification.
6. Install lower mount of shock absorber, then the stabilizer, ensuring .40-.47 inch (10-12mm) of thread is exposed at upper part of stabilizer.
7. Install hub and disc plate assembly and adjust wheel bearing, tightening locknut until preload is 1.3-2.6 lbs.
8. Install bearing set plate using two bolts.
9. Coat spacer with suitable grease and install spacer and snap ring.
10. Install caliper assembly, torquing to specification.
11. Install wheel and freewheel hub, torquing lug nuts and freewheel hub to specification.