Front Axle Replacement

WARNING:
^ When lowering or repositioning axle, an additional two persons are required.
^ Before commencing work, depressurize air suspension.

REMOVAL
1. Remove brake pads.
2. Remove 2 bolts securing each brake caliper assembly to steering knuckles. Release caliper Tie aside.

CAUTION: If a sensor is removed for any reason, a NEW sensor bush must be installed.

3. Remove ABS sensors and brake hoses from steering knuckles






4. Remove nut securing drag link to steering knuckle Release taper joint.
5. Remove bolt securing panhard rod to axle. Release panhard rod. Tie aside.
6. Remove anti roll bar.
7. Remove 2 nuts securing track rod ball joints to steering knuckles. Release taper joints. Remove track rod.
8. Mark differential and propeller shaft flanges to aid reassembly.






9. Remove 4 nuts and bolts securing propeller shaft to differential; discard nuts. Release shaft and tie aside.






10. Release height sensors from radius arms.






11. Remove banjo bolt securing breather hose to axle case. Collect sealing washers. Plug hose and connection.
12. Support front axle.






13. Remove bolts securing air spring retaining pins. Remove pins.
14. Release air springs from axle.






15. Remove 2 nuts securing shock absorbers to axle. Release shock absorbers. Collect mounting rubbers.






16. Remove 2 nuts securing radius arms to chassis brackets.
17. With assistance, lower and move axle forward. Release radius arms from chassis brackets. Collect rubber bushes.
18. Remove axle from vehicle.
19. Remove 2 nuts and bolts securing each radius arm. Remove radius arms.

INSTALLATION
20. Ensure mating faces are clean.
21. Position radius arms to axle. Secure with nuts and bolts. Tighten to 125 Nm (92 ft. lbs.).
22. Position axle under vehicle.
23. With assistance, raise axle, locating radius arms and rubber bushes into chassis locations.
24. Secure radius arms with nuts. Tighten to 160 Nm (118 ft. lbs.).
25. Position shock absorbers with mounting rubbers to axle. Secure with nuts. Tighten to 45 Nm (33 ft. lbs.).
26. Align air springs. Install securing pins. Install pin retaining bolts. Tighten to 20 Nm (15 ft. lbs.).
27. Remove plugs from breather hose and connections. Secure to axle with banjo bolt and new sealing washers.
28. Connect height sensor links to radius arms.
29. Position propeller shaft to differential flange. Align marks.
30. Secure propeller shaft with bolts and new nuts. Tighten to 48 Nm (35 ft. lbs.).
31. Position track rod to steering knuckles. Secure with nuts. Tighten to 80 Nm (59 ft. lbs.).
32. Install anti roll bar.
33. Position panhard rod. Secure with bolt. Tighten to 200 Nm (148 ft. lbs.).
34. Position drag link on steering knuckle. Secure with nut. Tighten to 80 Nm (59 ft. lbs.).
35. Lightly coat ABS sensors with silicone grease.
36. Install ABS sensors, new bushes and brake hoses to steering knuckles.
37. Position caliper assemblies to steering knuckles. Secure with bolts. Tighten to 220 Nm (162 ft. lbs.).
38. Install brake pads.
39. Replenish axle oil.