4 Wheel Drive
Fig. 17 Using puller to remove tie rod (Typical):
Fig. 18 Using puller to remove drag link from steering arm. (Typical):
MODELS W/FULL TIME 4WD
Removal & Disassembly
1. Remove axle shaft cotter pin and loosen outer axle shaft nut.
2. Raise vehicle, then remove wheel assembly.
3. After removing caliper retainer and anti-rattle spring assembly, slide caliper out and away from rotor. Hang caliper out of the way. Do not allow caliper to hang by hydraulic brake hose. Remove inboard brake pad.
4. Remove outer axle shaft nut and washer and through access hole in rotor assembly; remove the six bearing retainer bolts.
5. Secure a suitable puller to wheel studs and tighten main screw of tool to remove hub, rotor, bearings, retainer and outer seal as an assembly. Remove puller from rotor.
6. Remove brake caliper adapter from knuckle, then remove and discard O-ring from knuckle, if equipped.
7. Carefully pull axle shaft assembly out and remove seal and slinger from shaft.
8. Disconnect tie rod from steering knuckle using a suitable tool, so as not to damage seal.
9. On left side only, disconnect drag link from steering knuckle arm again using a suitable tool to avoid seal damage.
10. Remove nuts from steering knuckle arm on left side only. Tap arm to loosen tapered dowels. Remove dowels and arm.
11. Remove cotter pin from upper ball joint nut then remove upper and lower ball joint nuts. Discard lower nut.
12. Separate steering knuckle from axle housing yoke using a brass drift and a hammer, then, using a suitable tool, remove and discard sleeve from upper ball joint yoke on axle housing.
13. Secure steering knuckle uPSIde down in a vise and remove snap ring from lower ball joint.
14. Use proper tools to press upper and lower ball joints from steering knuckle. Replace ball joints if any looseness or endplay exists.
Fig. 9 Installing seal slinger on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Fig. 10 Installing lip seal on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Fig. 11 Using pry bar to retain axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Assembly & Installation
1. Secure steering knuckle right side up in a vise and press upper and lower ball joints into position using proper tools. Install snap ring on lower joint and new boots on both joints.
2. Thread new sleeve into ball joint yoke on axle housing ensuring that two threads are exposed at the top.
3. Position steering knuckle on axle housing yoke, then install a new lower ball joint nut and torque to 80 ft-lbs.
4. Use Tool No. C-4169 and a torque wrench to torque sleeve in upper ball joint yoke to 40 ft-lbs, then install upper ball joint nut and torque to 100 ft-lbs. Install cotter pin if slot in nuts and hole in stud align. If not, tighten, do not loosen nut to align.
5. On left side only, position steering knuckle arm over studs on steering knuckle. Install tapered dowels and nuts, then torque nuts to 90 ft-lbs. Secure drag link to steering knuckle arm and torque nut to 60 ft-lbs.
6. Secure tie rod end to steering knuckle. Torque nut to 45 ft-lbs.
7. Install brake dust shield, if removed.
8. Inspect outer axle shaft seal surface for grooving. If surface is grooved, repair as described in "Servicing Rotor Hub or Bearings".
9. Apply RTV sealer to seal surface of axle shaft then using driver, C-4398-1, install seal slinger with lip toward splines onto outer axle shaft.
10. Carefully insert axle shaft into housing so as not to damage differential seal at side gears. After sliding axle shaft completely in, wedge a pry bar through universal joint to retain shaft.
Fig. 12 Using driving & adapter to install seal cup into knuckle. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Fig. 13 Tools in place after seal cup is installed. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Fig. 15 Forming a seal on bearing retainer face. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes. Models w/full time 4WD:
11. Install seal cup using adapter C-4398-2, and driver C-4398-1. Use a small amount of wheel bearing grease on adapter face to hold cup in position, then drive cup until bottomed in knuckle. Do not remove tool at this time.
12. Apply a 1/4 inch bead of RTV sealer to retainer face on the chamfer. This replaces the O-ring discarded during disassembly.
13. Carefully remove seal installing tool from knuckle bore so that outer axle shaft remains centered. If shaft is moved, ensure that lip seal is still riding inside cup. Correct if necessary.
14. Before installing hub, rotor, retainer and bearing assembly on knuckle, position bearing retainer in hub so that grease fitting is facing forward, if equipped. Use a crossing method and torque retainer plate bolts to 30 ft-lbs. Bearing retainers that have a grease fitting must be positioned on knuckle so that fitting is facing directly forward.
15. Install brake adapter and remove any pry bar from universal joint.
16. Install axle shaft washer and nut. Torque nut to 100 ft-lbs. and continue to tighten nut until next slot in nut aligns with hole in axle shaft. Install cotter pin.
17. Through the access hole in hub, lubricate fitting in bearing retainer with multipurpose grease until grease flows through new inner seal. Seal may be viewed through universal joint area. Spin hub several times and lubricate fitting again. Grease must flow from 1/2 of seal diameter.
18. Replace brake caliper assembly and wheel, then lower vehicle and test operation.
MODELS LESS FULL TIME 4WD
Removal & Disassembly
1. Remove locking hub assembly, if equipped.
2. Raise vehicle and remove wheel assembly.
3. Remove caliper retainer and anti-rattle spring assemblies.
4. Remove caliper from disc and support caliper to prevent damage to brake line.
5. Remove the inboard brake pad and disc.
6. Remove the caliper adapter from knuckle.
7. Remove the six nuts and washers from spindle to steering knuckle attaching bolts.
8. Remove brake splash shield.
9. Tap spindle lightly with soft faced hammer to free from steering knuckle.
10. Upon removal, examine bronze spacer between needle bearing and shaft joint assembly. If wear is evident, replace.
11. Clamp spindle in vise avoiding bearing carrying surfaces. Remove needle bearing grease seal.
12. Using a suitable puller remover inner axle needle bearings. On 1985-87 models, left spindle does not have needle bearings.
13. Carefully remove axle shaft, axle seal and stone shield, if equipped.
14. Remove the tie rod from the steering knuckle.
15. On the left side only, remove drag link from steering knuckle.
16. On the left side only, remove the nuts and cone washers from steering knuckle arm. Tap the steering knuckle arm to free knuckle. Remove arm.
17. Remove cotter pin from upper ball joint nut. Remove upper and lower ball joint nut. Discard lower nut.
18. Using a brass drift and hammer separate steering knuckle from axle housing yoke. Remove sleeve from upper ball joint using tool C-4169. Discard sleeve.
19. Install steering knuckle in vise and remove snap ring from lower ball joint with suitable snap ring pliers.
20. Using tool C-4212-1 and adapter set C-4288, press lower ball joint from steering knuckle.
21. Reposition tool, and press upper ball joint from steering knuckle. Replace ball joints if any looseness or end play exists.
Cleaning & Inspection
1. Clean all parts using a suitable solvent.
2. Blow dry parts using compressed air.
3. Inspect all parts for cracks, wear, chips, burrs and distortion.
4. Replace any parts not suitable for further service.
Assembly & Installation
1. Position steering knuckle right side up in a vise. Using tool C-4212-1 and adapter set C-4288, press the lower ball joint into position.
2. Using the same tool and adapter set as above, install the upper ball joint.
3. Install new boots on the ball joints and remove the steering knuckle from the vise.
4. Screw a new sleeve into the upper ball joint yoke leaving two threads showing at the top.
5. Position steering knuckle on axle housing yoke and torque new lower ball joint nut to 80 ft-lbs.
6. Using tool C-4169 and a torque wrench, torque sleeve in upper ball joint to 40 ft-lbs. Install upper ball joint and torque to 100 ft-lbs. Align slot in nut with hole in stud and install cotter pin. Do not loosen to align.
7. On left side only, position steering knuckle arm over studs on steering knuckle. Install cone washers and nuts and torque to 90 ft-lbs.
8. Install drag link on steering knuckle arm and torque to 60 ft-lbs. Install cotter pin.
9. Install the rod end to steering knuckle. Torque nut to 45 ft-lbs. and install cotter pin.
10. Install lip seal on stone shield with lip toward axle shaft spline.
11. On all except 1986-87 left side, carefully insert axle shaft into housing. Avoid damaging differential seal at right side gear or axle shaft seal on left side gear.
12. On 1986-87 left side, proceed as follows:
a. Remove disconnect housing cover, then position shift collar onto splined end of inner axle shaft.
b. Install intermediate axle shaft through axle shaft seal. Use caution not to damage seal.
c. Install disconnect housing cover assembly and gasket. Ensure shift fork is guided into groove of shift collar.
d. Install disconnect cover shield and shield attaching bolts. Torque bolts to 10 ft-lbs.
e. Connect vacuum lines and switch electrical connector.
13. Using tools D-122 and C-4171, install new needle bearings into spindle.
14. Fill seal area with NLGI grease or equivalent, and install seal with tools D-155 and C-4171.
15. Install new bronze spacer on axle shaft, install spindle and brake splash shield.
16. Install new nuts and torque to 25-35 ft-lbs.
17. Mount braking disc assembly and outer wheel bearing cone onto spindle.
18. Install wheel bearing nuts and locking washer.
19. Install locking hub assembly.
20. Install brake adapter and torque attaching bolts to 85 ft-lbs.
21. Install the assembled brake caliper assembly.
22. Install the wheel and torque the nuts to 110 ft-lbs. Lower vehicle and test operation.