Axle Assembly - Front

Axle Assembly - Front








Special Tool(s)

Removal and Installation
1. Place the selector lever in the NEUTRAL position.
2. Remove front wheel and tire assemblies.





3. WARNING: Remove the brake pads, or tape them to the anchor plate, to prevent them from failing out of the anchor plate. Failure to follow these instructions may result in personal injury or component damage.

CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose.

NOTE: Install a wheel nut to secure the brake disc in place.

Remove the bolts and position the front disc brake calipers aside.





4. Remove the cotter pin and the nut from each tie-rod end. Discard the cotter pins and nuts.





5. Using the special tool, separate the outer tie-rod ends from the knuckles.





6. Remove the nut from each upper ball joint. Discard the nut.





7. CAUTION: Do not allow the knuckle to hang freely. It is possible to overextend and internally separate the inner CV joint from its housing.

Using the special tool, disconnect the upper ball joints from the knuckles.





8. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

NOTE: The LH inboard CV joint housing will not separate completely from the axle at this time.

NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.

Using the special tool, disengage the LH inboard CV joint housing from the differential side gear.





9. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

NOTE: A circlip retains the inboard CV joint housing to the axle shaft in the axle tube.

Using the special tool, disengage the RH inboard CV joint housing from the axle tube.





10. CAUTION: Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing, or the axle shaft splines.

CAUTION: Install a new retainer circlip on the outboard splined end of the axle shaft before reseating the axle shaft in the differential side gear.

Pull the knuckle, the halfshaft, and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft.





11. Using the special tool, plug the axle tube.

12. CAUTION: Index-mark the front axle pinion flange and the front driveshaft, and the front output shaft and the front driveshaft constant velocity joint.

CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear.

CAUTION: Tape the bearing cups to prevent them from failing off the spider.

Remove the front driveshaft.





13. Remove the stabilizer bar links.





14. Remove the nuts and brackets retaining the stabilizer bar to the frame. Remove the stabilizer bar or wire it to the rear crossmember.





15. WARNING: Secure the axle to the jack with a safety strap. Failure to follow these instructions may result in personal injury.

Secure the differential housing to a suitable lift.











16. CAUTION: Anytime bolts, washers, spacers, or nuts are loosened in the front differential support for any reason, install new components to prevent damage.

Remove the bolts and nuts retaining the axle to the frame. Discard the bolts and nuts.
17. Lower the axle approximately 25 mm (1 inch). Guide the LH halfshaft out of the axle while moving the axle approximately 25 mm (1 inch) to the RH (passenger) side of the vehicle.





18. Disconnect the vent hose from the differential housing vent tube.
19. Lower the axle from the vehicle.

20. CAUTION: Install a new retainer circlip on the left inboard CV joint housing and on the right-hand axle shaft.

CAUTION: Check the retainer circlip engagement after installing the RH axle shaft and each halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.

CAUTION: Install new bolts, washers, spacers and nuts in the front differential support bushing.

NOTE: Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If new bolts are not available, coat the threads of the original bolts with threadlock.

To install, reverse the removal procedure.
Check and, if necessary, fill the axle with axle lubricant to 9.56 mm (0.38 inch) below the bottom of the axle fill hole.