Axle Shaft Assembly: Service and Repair

REMOVAL PROCEDURE





1. Unlock the steering column so that the steering linkage is free to move.
2. Raise the vehicle. Support the vehicle with suitable safety stands.
3. Remove the front tires and wheels.





4. In order to prevent the drive axle from turning, insert a drift through the brake caliper and into one of the rotor vanes.





5. Remove the axle nut and washer.





6. Remove the drift from the brake rotor. Support the caliper with a piece of wire in order to prevent damage to the brake hose.
7. Remove the caliper. Refer to Brake Caliper Replacement (Front Wheel) in Disc Brakes.
8. Remove the rotor. Refer to Brake Rotor Replacement (Front Wheel) in Disc Brakes.





9. Remove the brackets from the upper control arm holding both the ABS wire and the brake hose.
10. Remove the ABS bracket located on the top of the upper control arm ball joint.





11. Strap the frame to the hoist in order to prohibit movement.

Notice: Be careful that the safety stand does not damage or bend any components it may contact.





12. Position a safety stand under the lower control arm.
13. Support the weight of the steering knuckle assembly and lower control arm with a





14. Disengage the axle shaft from the hub by placing a brass drift against the outer end of the drive axle in order to protect the threads. Sharply strike the brass drift with a hammer. Do not attempt to remove the axle at this time.





15. Support the steering knuckle and assembly with a piece of wire in order to prevent damage to the outer tie rod and ABS wire.
16. Remove the upper ball joint. Refer to Upper Ball Joint Replacement (FWD) or Upper Ball joint Replacement (S4WD) in Front Suspension.
17. Remove the shock absorber from the lower mount only. Refer to Shock Absorber Replacement (RWD) or Shock Absorber Replacement (S4WD) in Front Suspension.
18. Remove the lower ball joint. Refer to Lower Ball Joint Replacement (RWD) or Lower Ball Joint Replacement (S4WD) in Front Suspension.

Important: After the lower bail joint is loose from the knuckle, simultaneously push the axle shaft in toward the differential carrier in order to allow room for the knuckle and assembly to be removed.

19. Remove the axle from the steering knuckle assembly.

Important: Lower the safety stand from the lower control arm in order to relieve the pressure of the torsion bar and in order to allow for clearance.
Do not damage the axle seal during removal of the differential carrier shield.





20. Remove the front differential carrier shield.





21. Disconnect the left drive axle shaft from the differential carrier by placing a block of wood or a brass drift against the tripot housing. Firmly strike the block of wood outward from the case with a hammer. Strike hard enough to overcome the snap ring pressure holding the shaft in.





22. Disconnect the right drive axle shaft from the differential carrier by placing a block of wood or a brass drip against the tripot housing. Firmly strike the block of wood outward from the case with a hammer. Strike hard enough to overcome the snap ring pressure holding the shaft in.





23. Pull the axle straight out from the differential carrier.
24. Support the drive axle so as not to tear the boot.
25. Remove the drive axle.

Caution: Do not allow the vehicles weight to load the front wheels, or attempt to operate the vehicle, when the drive axle(s) or hub nut(s) are removed. To do so may cause the front wheel bearing inner races to separate, resulting in damage to front brake and suspension components and/or personal injury.

INSTALLATION PROCEDURE
Do not lubricate or damage the differential carrier axle seals during installation.





1. In order to prevent damage to the boot, cover the following components with a shop towel:
- The shock mounting bracket
- The lower control arm ball stud
- All other sharp edges

2. Install the axle shaft to the differential carrier.
2.1 With both hands on the tripot housing, align the splines on the shaft with the differential carrier.
2.2 Center the drive axle into the differential carrier seal.
2.3 Firmly push the shaft straight into the differential carrier until the snap ring seats into place.





Notice: Be careful that the safety stand does not damage or bend any components it may contact.

3. Raise the safety stand to support the weight of the lower control arm.
4. Assemble the lower ball joint. Refer to Lower Ball Joint Replacement (RWD) or Lower Ball Joint Replacement (S4WD) in Front Suspension.

Important: It will be necessary to slightly start the knuckle onto the drive axle while simultaneously guiding the lower ball stud to its proper location on the steering knuckle.

5. Install the lower shock mount. Refer to Shock Absorber Replacement (RWD) or Shock Absorber Replacement (S4WD) in Front Suspension.
6. Install the upper ball joint. Refer to Upper Ball Joint Replacement (RWD) or Upper Ball Joint Replacement (S4WD) in Front Suspension.





7. Install the drive axle washer and nut.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the drive axle nut.

Tighten the bolts to 140 Nm (103 ft. lbs.).





9. Install the ABS bracket located on the top of the upper control arm ball joint.
10. Install the brackets from the upper control arm holding both the ABS wire and the brake hose.
11. Install the caliper. Refer to Brake Caliper Replacement (Front Wheel) in Front Disc Brakes.
12. Install the rotor. Refer to Brake Rotor Replacement (Front Wheel) in Front Disc Brakes.
13. Install the tires and wheels.
14. Remove the safety stands.





15. Install the front differential carrier shield.

Notice: Refer to Fastener Notice in Service Precautions.

16. Install the front differential carrier shield bolts.

Tighten the bolts to 25 Nm (19 ft. lbs.).

17. Remove the strap from the frame.
18. Lower the vehicle.