All Wheel Drive (AWD) Front Axle

AWD Front Axle Components:

Axle Components - Legend:

REMOVE OR DISCONNECT















1. Battery and battery tray.
2. Shift cable from the vacuum actuator.
^ Unlock the steering column so the linkage is free to move.
^ Raise the vehicle and support with safety stands.
3. Front wheels.
4. Front differential carrier body shield, if equipped.
5. Right side caliper.
6. Right upper ball joint.
A. Support the right lower control arm.
B. Unload torsion bar.
C. Disconnect the ball joint.
D. Remove the support so the control arm will hang free.
E. Insert a drift through the opening in the top of the brake caliper into the vanes in the brake rotor. This will keep the axle from turning.

Important: It is essential that the positions of all driveline components relative to the propeller shaft and axles be observed and accurately reference marked prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. Specifications and torque values, as well as any measurements made prior to disassembly, must be followed.

7. Bolts. Then remove the drift from the brake rotor.

8. Wire from indicator switch.
9. Shift cable housing and shift cable.
10. Bolts, nuts, and washers.
11. Remaining two upper bolts.
12. Shaft and tube, by working it around the drive axle. Do not allow the thrust washers, carrier connector, sleeve, or output shaft to fall out of the carrier assembly or become damaged.

DISASSEMBLE
^ Tools Required:
- J 29369-2 Bearing Remover

1. Shaft.
A. Hold the tube in a vise by the mounting flange.
B. Tap the shaft out with a soft mallet.
2. Deflector.
3. Seal using a seal removal tool.
4. Bearing with J 29369-2 and a slide hammer.
5. Shift cable housing seal.
- Drive out with a punch.
6. Retaining ring and output shaft.
7. Pilot bearing.

ASSEMBLE
^ Tools Required:
- J 33799 Shift Cable Housing Seal Installer
- J 33844 Bearing installer
- J 42212 Shaft Seal Installer






1. Pilot bearing.
2. Output shaft and retaining ring.





3. Seal using J 33799.
4. Bearing using J 33844.
- When the tool is flush with the tube end, the bearing is installed to the proper depth. Lubricate the bearing with axle lubricant.





5. Seal with J 42212.
A. Drive the seal in until the seal flange is flush with the tube end.

CAUTION: Do not apply lubricant to seals or sealing surfaces of the drive axle. Applying lubricants will cause premature wear of the axle seal.

Important: It is essential that the positions of all driveline components relative to the propeller.

6. Deflector.
7. Shaft.

Clean
- Sealing surfaces of tube and carrier assembly with a chlorinated solvent.

INSTALL OR CONNECT
^ Tools Required:
- J 33798 Hub Engagement Tool

^ Apply a bead of sealer to the carrier sealing surface.
^ Make sure the washer, output shaft, sleeve, thrust washer, and carrier connector are in place in the carrier assembly.

1. Thrust washer to the tube as shown. Use grease to hold it in place.
2. Shaft and tube assembly to the carrier.
3. Bolt at the one o'clock position. Leave finger tight.
- Pull the shaft and tube assembly down until the remaining bolts can be installed.
4. Shift cable housing and remaining bolts.
- Tighten bolts to 48 Nm (36 ft. lbs.).
5. Bolts, washers, and nuts.
- Tighten nuts to 98 Nm (72 ft. lbs.).

Inspect
- Operation of shift mechanism. Use J 33798. Insert the tool into the shift fork and check for rotation of the axle shaft.

6. Shift cable.
7. Wire to the indicator switch.
8. Upper ball joint.
9. Drive axle to the shaft.
10. Bolts
A. Install one bolt finger tight.
B. Rotate the axle shaft to install the remaining bolts.
C. Hold the axle shaft by inserting a drift in the top of the brake caliper and into the vanes of the brake rotor.

Tighten
^ Bolts to 83 Nm (61 lb. ft.).
^ Remove the drift from the brake rotor.

11. Caliper assembly.
12. Front axle under body shield.
13. Front wheels.

Inspect
- Axle lubricant level, and add lubricant as necessary.
- Lower the vehicle.

9. Shift cable to the vacuum actuator.
10. Battery and battery tray.