Replacement

Removal Procedure





1. Turn the ignition switch to the OFF position to unlock the steering column.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove front shield if equipped. Refer to Shield Replacement.
4. Drain front Differential. Refer to Lubricant Change.
5. Install plastic tie straps loosely over the ends of the front stabilizer shaft and under the center of each halfshaft bar. Do not tighten.

Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. All components must be reassembled in the exact location to each other as they were when removed.

6. Reference mark the relationship of the propeller shaft to the front axle.
7. Remove the front propeller shaft retainers.
8. Remove the front propeller shaft from the front axle yoke and secure it out of the way.
9. For some models, remove the engine oil filter.





10. Remove the bolts (1) securing the halfshaft flanges to the differential assembly.
11. Remove the pitman arm from the relay rod. Refer to Pitman Arm Replacement (S4WD) in Steering and Suspension.
12. Move pitman arm to the left for clearance.
13. Push relay rod forward and up for clearance.
14. Support the front differential.





15. Remove the front drive axle inner shaft housing nuts (3), washers (2), and bolts (1) from the differential mounting bracket.
16. Disconnect front axle actuator connector.
17. Remove the vent hose from the front axle.

Important: Place plastic tie straps around the center of the halfshaft assembly, contacting only the halfshaft bar.

18. Tighten the plastic tie straps to support the inner halfshaft ends.





19. Remove upper differential carrier mounting nut (5), washers (6) and bolt (8).
20. Remove lower differential carrier mounting nut (3), washers (2), and bolt (9).
21. Remove front axle from vehicle.

Installation Procedure





1. Install front axle to vehicle.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the upper differential carrier mounting bolt (8), washers (6), and nut (5). Do not tighten.
3. Install the lower differential carrier mounting bolt (9), washers (2), and nut (3). Do not tighten.





4. Install the front drive axle inner shaft housing bolts (1), washers (2), and nuts (3). Do not tighten.
5. Tighten the front differential mounting fasteners.

Important: Tighten the fasteners in the specified order to ensure that the differential is aligned properly within the vehicle.

5.1. Tighten the upper differential carrier mounting bolt to 90 Nm (70 ft. lbs.).
5.2. Tighten the lower differential carrier mounting bolt to 90 Nm (70 ft. lbs.).
5.3. Tighten the front drive axle inner shaft housing nuts to 90 Nm (70 ft. lbs.).
6. Remove front axle support fixture.
7. Install the vent hose to the front axle.
8. Connect the front axle actuator connector.
9. Install pitman arm stud to the relay rod. Refer to Pitman Arm Replacement (S4WD) in Steering and Suspension.
10. Install the engine oil filter if necessary.





11. Install the front drive axle propeller shaft to the front axle yoke.
12. Install the front drive axle propeller shaft retainers and bolts.
Tighten the propeller shaft bolts to 20 Nm (15 ft. lbs.).





13. Install the halfshaft flange bolts (1) to the differential assembly.
Tighten the halfshaft flange bolts to 78 Nm (58 ft. lbs.).
14. Fill front axle. Refer to Lubricant Change.
15. Install front shield if equipped. Refer to Shield Replacement.
16. Lower the vehicle.
17. Add engine oil as necessary. Refer to Fluid and Lubricant Recommendations.