Shaft Intermediate

SHAFT INTERMEDIATE

REMOVAL
1. Remove half shaft from disconnect side of the axle.
2. Remove disconnect actuator wiring connector.





3. Remove disconnect actuator (1) bolts (2) and remove actuator.





4. Remove O-ring (1) and snap ring (2) from output shaft.





5. Remove disconnect seal (1) bolts (2).





6. Remove output shaft (1) and disconnect seal (2) with Remover 8420A (3) and Slide Hammer C3752.





7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket.
8. Remove differential cover.





9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2).





10. Remove intermediate shaft (1) from axle tube (2).

DISASSEMBLY
1. Secure intermediate shaft in vise.





2. Remove output shaft bearing from intermediate shaft (2), with Puller 9585 (1) and Slide Hammer C637.

ASSEMBLY





1. Install output shaft bearing (1) in intermediate shaft (3) with Installer 9768 (2) and Handle C4171.

CAUTION: Bearing must be installed with lettering facing outwards. Failure to follow these instructions will damage the bearing.

INSTALLATION
1. Install new intermediate shaft snap ring.





2. Install shaft (1) into axle tube (2) and side gear. Verify intermediate shaft snap ring is seated in side gear.





3. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2).





4. Position disconnect collar (1) on intermediate shaft (2), so collar is in 2WD position.





5. Verify output shaft bearing cup (1) is seated in the disconnect pocket (2).





6. Install output shaft (1) with bearing into disconnect pocket (2).





7. Install disconnect seal (1) on output shaft (2).





8. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2).





9. Install disconnect seal (1) in disconnect pocket with Installer 6761 (2) and a hammer.





10. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.).





11. Install output shaft O-ring (1) and snap ring (2).





12. Clean actuator (1) sealing surface and install new gasket (2) if necessary.





13. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket.





14. Install disconnect actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.).
15. Install disconnect actuator wiring connector.
16. Install differential cover and fill differential to specification.
17. Install half shaft.