Service Procdure
SERVICE PROCEDUREREMOVAL
1. Lift the vehicle with a chassis/frame hoist. Shift the transmission into neutral and release the parking brake. This is to allow free movement to the propeller shafts during the removal and installation procedure.
(Front Flange)
2. Remove the protector plate from the transfer case.
3. Apply alignment marks on the flanges of these coupling points:
^ Front differential-to-front propeller shaft (Figure 1)
^ Front propeller shaft-to-front propeller shaft adapter (Figure 2)
^ Front propeller shaft adapter-to-front output flange of the transfer case (Figure 2)
4. Remove the (6) 8 mm Allen head bolts, nuts and washers from each end of the front propeller shaft, and remove the front propeller shaft.
5. Remove the (4) 14 mm bolts, nuts and washers from the front propeller shaft adapter, and remove the adapter from the front output flange of the transfer case. (Figure 3)
(Rear Flange)
6. To ensure correct alignment of the flange when reinstalling the propeller shaft, apply alignment marks on the flanges of these coupling points:
^ Rear differential-to-rear propeller shaft (Figure 4)
^ Rear propeller shaft-to-rear output flange of the transfer case (Figure 5)
7. Remove the (4) 14 mm bolts, nuts and washers from each end of the rear propeller shaft, and remove the rear propeller shaft.
INSPECTION
Refer to INSPECTION FLOWCHART for quick reference of this inspection procedure.
(Front Flange)
1. Inspect the 3O mm front output flange lock nut for staking marks on the side of the nut. (Figure 6)
^ If stake marks exist, then skip to Step 7.
2. Remove and inspect the un-staked 3O mm lock nut, flange seal,
washer, and flange.
^ If there is no evidence of damage, skip to Step 5.
3. Inspect oil seal for damage.
4. Replace all damaged parts.
NOTE
If serious damage(s) to the vehicle exists, contact your Zone Service and Parts Manager for further instructions.
5. Reassemble and install a new lock nut.
^ Using a flange holder (J-8614-1), torque the 3O mm lock nut to 123 lb.ft. (167 N-m).
6. Stake the newly installed lock nut.
^ Using a punch (J-39209), firmly stake the two ends of the lock nut. (Figure 7)
(Rear Flange)
7. Inspect the 30 mm rear output flange lock nut for staking marks on the side of the nut.
^ If stake marks exist, then skip to Installation procedure. (Figure 8)
8. Remove the speedometer driven gear assembly and inspect the driven gear for any signs damage.
^ If there is no evidence of damage, reinstall the speedometer driven gear assembly and skip to Step 12.
9. Remove and inspect the un-staked 3O mm lock nut, flange seal, washer, and flange.
^ If there is no evidence of damage, reassemble and skip to Step 12.
10. Inspect oil seal for damage.
11. Replace any damaged parts and reassemble.
NOTE
If serious damage(s) to the vehicle exists, contact your Zone Service and Parts Manager for further instructions.
12. Install a new lock nut.
^ Using a flange holder (J-8614-1), torque the 3O mm lock nut to 123 lb.ft. (167 N-m).
13. Stake the newly installed lock nut.
^ Using a punch (J-39209), firmly stake the two ends of the lock nut. (Figure 7)
INSTALLATION
(Front Flange)
1. Ensure the connecting surfaces of the front propeller shaft adapter and the flange coupling on each end are clean so no foreign matter will be caught in between.
2. Reinstall the front propeller shaft adapter.
^ Tighten the bolts to the specified torque of 46 lb. ft. (63 N-m)
3. Reinstall the front propeller shaft:
^ Align each flange of the front propeller shaft with the alignment marks placed during removal.
^ Tighten the front propeller shaft adapter-to-front output flange attachment bolts to the specified torque of 46 lb. ft. (63 N-m)
^ Tighten the front propeller shaft-to-front differential attachment bolts to the specified torque of 32 lb. ft. (43 N-m)
4. Reinstall the protector plate to the transfer case.
(Rear Flange)
5. Ensure the connecting surfaces of the flange coupling on each end are clean so no foreign matter will be caught in between.
6. Reinstall the rear propeller shaft:
^ Align each flange of the rear propeller shaft with the alignment marks placed during removal.
^ Tighten the bolts to the specified torque of 46 lb. ft. (63 N-m)
7. Lower the vehicle from the hoist, and shift the transmission to the "Park" position.
APPLYING THE CAMPAIGN LABEL
1. Using a ball-point pen, fill out the following information on a campaign label (Part # 2-90028-700-0). Figure 9
^ This safety campaign number:
98V-180
^ Dealer Code
^ Repair Date: (Month/Day/Year)
2. Affix the campaign label adjacent to the manufacturer's identification label located on the driver's side B-pillar.