Replacement

DIFFERENTIAL CARRIER (R&R DIFFERENTIAL ASSEMBLY)

REMOVAL PROCEDURE





1. Remove the tire and wheel assembly.





2. Remove the engine protection shield.
3. Drain the front differential.





4. Remove the left and right antilock brake system (ABS) wiring harnesses from the retainers.





5. Disconnect the left and right wheel speed sensor electrical connectors.





6. Remove the brake hose retaining bolt from the frame. Left shown, right similar.





7. Disconnect the sway bar link pins from the lower control arms. Right shown, left similar.





8. Remove the steering gear. Service and Repair
9. Place an adjustable jack stand under the lower control arm. Left shown, right similar.





10. Remove the upper ball joint pinch bolt and nut. Right shown, left similar.
11. Remove the steering knuckle from the upper control arm. Left shown, right similar.





12. Remove the upper shock module bolts from the frame.
13. Lower the jack stand to allow removal of the steering knuckle from the upper control arm.
14. Remove the steering knuckle from the upper control arm.

IMPORTANT: In the following service procedures, it is not necessary to remove the wheel drive shaft from the steering knuckles.





15. Using a brass drift or equivalent, remove the left wheel drive shaft from the front differential.





16. Using a brass drift or equivalent, remove the right wheel drive shaft from the front differential.
17. Position the wheel drive shafts to the side.

IMPORTANT: DO NOT allow the shock modules and steering knuckle to hang without supporting them.

18. Using mechanics wire or metal hooks, secure the shock modules to the frame.
19. Remove the jack stand.

IMPORTANT: It is not necessary to completely remove the front propeller shaft from the vehicle.

20. Remove the front propeller shaft from the front pinion yoke. Propeller Shaft Replacement - Front
21. Relocate the propeller shaft to the side and secure.





22. Remove the inner axle shaft.
23. Remove the mounting bolts for the front differential assembly.
24. Remove the front differential assembly from the oil pan.





25. Secure the front differential to the frame.





26. Remove the oil pan assembly. Service and Repair





27. Remove the front differential from the vehicle.

INSTALLATION PROCEDURE





1. Position the front differential assembly on the frame.





2. Secure the front differential assembly.





3. Install the oil pan assembly.
4. Position the front differential on the oil pan.

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.






5. Install the differential bolts.

TIGHTEN
Tighten the bolts to 85 Nm (63 lb ft).

6. Install the inner axle shaft.
7. Position the adjustable jack stand under the lower control arm.
8. Remove the shock module from the secure position.
9. Install the right wheel drive shaft in the inner drive shaft.
10. Rinse the jack stand to allow the installation of the steering knuckle in the upper control arm. Right side shown, left similar.





11. Install the upper ball joint pinch nut and bolt.

TIGHTEN
Tighten the bolt and nut to 40 Nm (30 lb ft).

12. Remove the jack stand from under the lower control arm.





13. Install the front shock upper retaining nuts. Right shown, left similar.

TIGHTEN
Tighten the nuts to 45 Nm (33 lb ft).

14. Install the steering rack assembly.





15. Install the brake hose retaining bolt.

TIGHTEN
Tighten the brake hose retaining bolt to 25 Nm (18 lb ft).





16. Install the sway bar links to the lower control arm.





17. Connect the wheel speed sensors electrical connectors.





18. Install the left and right ABS wiring harnesses in the retainers.
19. Install the front propeller shaft.
20. Fill the front differential with fluid.





21. Install the engine protection shield.
22. Install the tires and wheels.