Clutch Cable Replacement - Front Drive Axle

Clutch Cable Replacement - Front Drive Axle






1. Remove the battery and the battery tray.
2. Remove the clutch cable hold down bolt attached to frame.
3. Disconnect the clutch cable from the retainer spring clip on the vacuum actuator.
4. Disconnect the clutch cable from the vacuum actuator bracket.
5. Raise the vehicle.
6. Remove the front differential carrier shield, if equipped.
7. Cut the strap holding the wire harness and the clutch cable together.






8. Disconnect the electrical connector from the four-wheel drive indicator switch.






9. Remove the three bolts from the clutch cable housing.






10. Separate the clutch cable housing from the differential carrier assembly.






11. Insert a screwdriver, or similar tool, into the clutch cable housing opening and disconnect the retainer spring from the clutch cable.






12. Remove the clutch cable and the clutch cable housing from the differential carrier assembly.






13. Disconnect the clutch cable coupling nut from the clutch cable housing.
14. Remove the clutch cable.

Installation Procedure






1. Install the clutch cable housing.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the clutch cable housing bolts. Tighten the clutch cable housing bolts to 48 Nm (36 lb ft).






3. Insert the clutch cable into the clutch fork. Engage the spring retainer in order to retain the clutch cable.
4. Install the clutch cable coupling nut to the clutch cable housing. Tighten the clutch cable coupling nut to 10 Nm (89 lb in).
5. Route the clutch cable to the vacuum actuator.
6. Connect the electrical connector to the four-wheel drive indicator switch.
7. Install the front differential carrier shield, if equipped.
8. Lower the vehicle.
9. Install the clutch cable hold down bolt. Tighten the cable hold down bolt to 17 Nm (13 lb ft).
10. Tie the cable and wire harness together with a tie strap.






11. Install the clutch cable to the vacuum actuator bracket. The clutch cable must engage the retainer spring on the vacuum actuator. The clutch cable lock tabs must engage the vacuum actuator bracket.
12. Install the battery and the battery tray.