Front Drive Axle

Removal

1. Raise vehicle on hoist.

2. Remove the front wheel/tire assemblies.

3. WARNING: REMOVE OR TAPE THE BRAKE PADS, TO PREVENT THEM FROM FALLING OUT OF THE CALIPER GUIDES.

CAUTION: Do not allow the calipers to hang by the hoses.

NOTE: Install a lug nut to secure each brake rotor in place.






Remove the brake caliper guide pin bolts and remove both calipers.

4. NOTE: Use care not to damage the tie-rod dust boots when installing the tool. Remove the adapter from the ball end of the tool. Apply a small amount of grease to the tie-rod stud and to the ball of the tool.






Remove both outer tie-rod end cotter pins and nuts. Separate the tie-rod ends, using Tie-Rod End Remover TOOL-3290-D.

5. Unclip the left and right wheel anti-lock sensor wiring harnesses from the locators on the vehicle chassis, located above the sway bar brackets.

6. WARNING: DO NOT ALLOW THE STEERING KNUCKLE TO HANG FREELY. IT IS POSSIBLE TO OVEREXTEND AND INTERNALLY SEPARATE THE INNER CV JOINT. SEPARATE BOTH AXLE HALFSHAFTS FROM THE FRONT AXLE.

CAUTION: Take necessary precautions to protect the machined sealing surfaces on each axle.





Remove both upper ball joint pinch bolts and disconnect the upper ball joints. Pull the axle halfshafts away from the axle with the steering knuckles.

7. Raise the vehicle.

8. Remove the lower engine splash shield.

9. WARNING: TAPE THE U-JOINT BEARING CAPS TO PREVENT THEM FROM FALLING OFF THE U-Joint. MARK THE LOCATION OF THE DRIVESHAFT.

Remove the front driveshaft U-joint bolts and secure the driveshaft out of the way.

10. Disconnect the electrical connector, vacuum line, and vent hose from the front axle housing.

11. NOTE: Use axle service plugs T95T-85O-A to plug the axle openings. Secure the axle housing to a suitable lift.

Remove the axle housing mounting bolts and lower the axle housing from the vehicle.

Installation

1. Remove the axle service plugs. Replace the circlip from the left axle halfshaft. (If the axle housing is not being replaced, replace the right axle shaft circlip.)

2. Raise the axle housing. Start the axle halfshafts into the axle housing. Install the axle housing bolts and tighten them to 66 Nm (49 lb-ft).

3. Remove the jack from the front axle housing.

4. Connect the electrical connector, vacuum line, and vent hose to the front axle housing.

5. Install the front driveshaft to the axle and the retaining bolts. Tighten the bolts to 19 Nm (14 lb-ft).

6. Install the lower engine splash shield.

7. Partially lower the vehicle.

8. CAUTION: Make sure the halfshaft circlips fully seat.

Install both axle halfshafts, using the steering knuckles to push the shafts into place. Install both upper ball joints into the steering knuckles. Install the pinch bolts and tighten them to 48 Nm (35 lb-ft).

9. Connect both wheel speed sensor wiring harnesses.

10. Install the outer tie-rod ends to both front wheel knuckles and install the castle nuts. Tighten the nuts to 91 Nm (67 lb-ft). Install a new cotter pin to each nut. If necessary, further rotate the nuts to line up with the holes in the tie-rod ends.

11. Install both brake calipers and guide pin bolts. Tighten the bolts to 33 Nm (24 lb-ft).

12. Fill the front axle with the correct type and quantity of lubricant.


13. Install the front wheel/tire assemblies.


14. Lower vehicle.