Removal and Installation

Removal

WARNING:
- Make sure jacks and safety stands are placed properly, and hoist brackets are attached to correct positions on the engine.
- Apply parking brake and block rear wheels so the vehicle will not roll off stands and fall on you while working under it.

CAUTION: Use fender covers to avoid damaging painted surfaces.

1. Remove the drain plug, and drain the differential oil.
2. Remove the cotter pins and castle nuts, than separate the ball joints from the lower arm using the special tool.
3. Remove the right damper pinch bolt, then separate the damper fork and damper.
4. Pry the driveshafts out of the differential and inter mediate shaft.

CAUTION:
- Do not pull on the driveshaft, as the inboard joint may come apart.
- Use care when prying out the assembly, and pull it straight to avoid damaging the differential oil seal or the intermediate shaft outer seal.

5. Pull on the inboard joint to remove the right driveshaft from the differential and to remove the left driveshaft from the intermediate shaft.
6. Remove the intermediate shaft assembly from the oil pan.





7. Tie plastic bags over the driveshaft ends.

NOTE: Coat all precision finished surfaces with clean engine oil.








8. Remove the 36 mm sealing bolt and O-ring, then disconnect the extension shaft from the differential using the special tool.

NOTE: Shift the transmission into the P Position to lock the secondary gear.





9. Remove the splash shield.





10. Remove the lower plate, then reinstall the steering gearbox mounting bolts.





11. Disconnect the Vehicle Speed Sensor (VSS) connector, then remove the VSS/power steering speed sensor.

NOTE: Do not disconnect the hoses.





12. Remove the air cleaner housing assembly.





13. Remove the power steering pump.

NOTE: Do not disconnect the hoses.





14. Disconnect the breather tube from the clamp, then remove the right exhaust manifold cover.





15. Remove the engine stop mount bracket bolts.
16. Attach the chain hoist to the engine.





17. Remove the right and left engine mount bracket nuts, then remove the right engine mount bracket.





18. Remove the right engine mount.





19. Remove the mounting bolts and 26 mm shim, then remove the differential assembly.

Installation

NOTE: If the differential case is replaced, the 26 mm shim must be adjusted (see step 1). If the differential case was not replaced, go to step 4.

1. Install the differential assembly.





2. Measure the clearance between the differential case and the torque converter housing.
3. Select the 26 mm shim from the following table.





26 mm SHIM





4. Install the two dowel pins on the differential assembly.





5. Attach the differential assembly to the engine, then tighten the four mounting bolts to the specified torque.
6. Install the 26 mm shim, then tighten the mounting bolts to the specified torque.





7. Install the right engine mount.





8. Install the right engine mount bracket, then right and left engine mount bracket nuts.
9. Remove the chain hoist.





10. Install the engine stop mount bracket bolts.





11. Apply Super High Temp Urea Grease (P/N 08798 - 9002) to the splines of the extension shaft, then install the new set ring.





12. Install the extension shaft using the special tool as shown.

NOTE: Push the extension shaft in the secondary driven gear shaft until the extension shaft stops.





13. Fill the secondary gear with Super High Temp Urea Grease (P/N 08798 - 9002).
14. Install the new O-ring in the groove of the 36 mm sealing bolt, then install the 36 mm sealing bolt.

NOTE: Shift the transmission into the P position to lock the secondary gear.





15. Install the right exhaust manifold cover, then install the breather tube to the clamp.





16. Install the power steering pump, then adjust the belt tension of pump belt.





17. Install the air cleaner housing assembly.





18. Install the Vehicle Speed Sensor (VSS)/power steering speed sensor, then connect the VSS connector.





19. Remove the steering gearbox mounting bolts, then install the lower plate and the steering gearbox mounting bolts.
20. Install the driveshafts and the intermediate shaft.

CAUTION: While installing the driveshaft and the intermediate shaft in the differential, be sure not to allow dust and other foreign particles to enter into the differential.

21. Install the damper fork, then install the right and left ball joints to the each lower arm with the castle nuts and new cotter pins.





22. Install the splash shield.
23. Refill the differential with the recommended oil.