Output Shaft: Service and Repair

INNER AXLE HOUSING SHAFT AND HOUSING REPLACEMENT
Removal Procedure





1. Remove the battery and the battery tray.
2. Remove the shift cable from the vacuum actuator. Refer to Shift Cable Replacement in Transfer Case.
3. Remove the right side drive axle. Refer to Front Drive Axle Assembly Replacement.

Important: Observe and accurately reference mark the positions of all driveline components relative to the propeller shaft and axles prior to disassembly. These components include the propeller shafts, drive axles, and related components. Reassemble all components in the exact relationship to each other as when you removed them. Follow specifications, torque values, and any measurements made prior to disassembly.

4. Remove the wire from the indicator switch.
5. Remove the shift cable housing and the shift cable. Refer to Shift Cable Replacement in Transfer Case.
6. Remove the bolts, nuts, and washers from the axle tube.
7. Remove the remaining two axle shaft upper bolts.
8. Remove the axle shaft and tube by working the shaft and tube around the drive axle. Do not allow the thrust washers, carrier connector, sleeve, or output shaft to fall out of the carrier assembly or become damaged.

Disassembly Procedure

- Tools Required
- J29369-2 Bearing Remover

1. Remove the axle shaft.
1.1. Hold the tube in a vise by the mounting flange.
1.2. Tap the shaft out with a soft mallet.
2. Remove the shaft deflector.
3. Remove the shaft seal using a seal removal tool.
4. Remove the bearing with J29369-2 and a slide hammer.
5. Remove the shift cable housing seal. Drive out the seal with a punch.
6. Remove the retaining ring and output shaft.
7. Remove the pilot bearing.

Assembly Procedure

- Tools Required
- J33799 Shift Cable Housing Seal Installer
- J33844 Bearing Installer
- J142212 Shaft Seal Installer

Important: Observe and accurately reference mark the positions of all driveline components relative to the propeller shaft and axles prior to disassembly. These components include the propeller shafts, drive axles, and related components. Reassemble all components in the exact relationship to each other as when you removed them. Follow specifications, torque values, and any measurements made prior to disassembly.

1. Install the pilot bearing.
2. Install the output shaft and retaining ring.

Caution: Do not apply lubricant to seals or sealing surfaces of the drive axle. Applying lubricants will cause premature wear of the axle seal.





3. Install the shaft seal using the J33799.
4. Install the shaft bearing using J33844. The bearing is installed to the proper depth when the tool is flush with the tube end. Lubricate the bearing with axle lubricant. Refer to Recommended Fluids and Lubricants in Specifications.





5. Install the seal with the J42212. Drive in the seal until the seal flange is flush with the tube end.
6. Install the shaft deflector.
7. Install the axle shaft.
8. Clean the sealing surfaces of the tube and carrier assembly with a chlorinated solvent.

Installation Procedure

- Tools Required
- J33798 Hub Engagement Tool

1. Apply a bead of sealer to the carrier sealing surface.
2. The washer, output shaft, sleeve, thrust washer, and the carrier connector must be in place in the carrier assembly.





3. Install the thrust washer to the tube as shown. Use grease to hold the washer in place.
4. Install the shaft and tube assembly to the carrier.
5. Install the shaft tube bolt at the one o'clock position. Leave the bolt finger tight.
6. Pull the shaft and tube assembly down in order to install the remaining bolts.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the shift cable housing and the remaining bolts.

Tighten the bolts to 48 Nm (36 ft. lbs.).

Notice: Refer to Fastener Notice in Service Precautions.





8. Install the bolts, washers, and nuts.

Tighten the nuts to 98 Nm (72 ft. lbs.).





9. Inspect the operation of the shift mechanism. Use J33798. Insert the tool into the shift fork. Check for rotation of the axle shaft.
10. Install the shift cable. Refer to shift Cable Replacement in Transfer Case.
11. Connect the wire to the shift indicator switch.
12. Install the right side drive axle. Refer to Front Drive Axle Assembly Replacement
13. Inspect the axle lubricant level. Add lubricant as necessary.
14. Lower the vehicle.
15. Install the shift cable to the vacuum actuator. Refer to shift Cable Replacement in Transfer Case.
16. Install the battery and the battery tray.