Front Differential
Axle Assembly - 4.4L, LHDService Repair No - 54.10.01
Special Service Tools
Removal
1. Disconnect the battery ground cable.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Raise and support the vehicle.
3. Remove the front wheels and tires.
4. Secure the hood in the service position.
^ Release the support struts.
5. Remove the engine cover.
6. Remove the air cleaner assembly.
7. Remove the steering gear.
8. Remove the front driveshaft.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
9. RH front: Disconnect the suspension height sensor link arm.
^ Remove the nut.
CAUTION: Support the lower arm.
10. RH front: Disconnect the lower arm.
^ Remove the bolt and discard the nut.
CAUTION: Support the tie rod.
11. RH front: Disconnect the tie rod.
^ Remove the bolt and discard the nut.
WARNING: Do not remove the nuts.
12. RH front: Release the air suspension spring.
^ Loosen the 3 nuts.
CAUTION: Support the halfshaft.
13. RH front: Using the special tool, release the halfshaft from the differential.
14. Remove the engine compartment LH heat shield.
^ Remove the 2 nuts.
^ Remove the 2 screws.
15. Using a transmission jack, raise the engine clear of the engine mount.
CAUTION: Always plug any open connections to prevent contamination.
16. Disconnect the differential case breather line.
WARNING: Fluid loss is unavoidable, use absorbent cloth or a container to collect the fluid.
NOTE:
The upper rear bolt will remain in the differential case.
17. Release the differential case.
^ Remove the nut securing the front driveshaft, joint shield.
^ Remove the 4 bolts.
18. Remove the front driveshaft joint shield.
^ With assistance, position the front differential case rearward.
^ Remove the 2 Torx screws.
19. LH front: Raise the stabilizer bar.
^ Secure the stabilizer bar in the raised position.
CAUTION: Make sure component mating faces are not damaged during removal.
NOTE:
The differential case is rotated by 90 degrees, and removed through the sub-frame with the halfshaft oil seal uppermost.
20. With assistance, carefully remove the front differential case.
^ Remove the bolt.
^ Remove and discard the O-ring seal.
^ Remove and discard the halfshaft oil seal.
21. Remove the retaining clip from the RH halfshaft.
Installation
1. Clean the component mating faces.
2. Install a new O-ring seal to the differential case.
^ Lubricate the O-ring seal with petroleum jelly.
3. Install a new clip to the RH halfshaft.
NOTE: Install the upper rear bolt to its location in the differential case.
4. With assistance, carefully install the front differential case.
^ Position the differential rearward of its location.
5. Install the front driveshaft joint shield.
^ Tighten the Torx screws to 3 Nm (2 ft. lbs.).
CAUTION: Make sure the O ring seal remains in its fitted position.
6. With assistance, align and secure the front differential case.
^ Engage the front drive shaft joint shield with its securing stud.
^ Align the dowel and tighten the bolts to 115 Nm (85 ft. lbs.).
^ Tighten the front drive shaft joint shield nut to 10 Nm (7 ft. lbs.).
7. Connect the differential case breather line.
8. Install the steering gear.
9. Remove the engine support.
10. Release the stabilizer bar.
CAUTION: Keep the halfshaft horizontal to avoid damaging the oil seal.
CAUTION: Pull on the halfshaft to make sure the clip has fully engaged and retains the halfshaft inboard joint within the differential case.
11. RH front: Fully install the halfshaft.
^ Remove the support.
^ Clean the component mating faces.
^ Lubricate the seal with clean differential fluid.
NOTE:
Do not tighten the locking nut at this stage.
12. RH front: Connect the tie rod.
^ Install the bolt with a new nut.
NOTE:
Do not tighten the locking nut at this stage.
13. RH front: Connect the lower arm.
^ Install the bolt with a new nut.
CAUTION: Make sure the hardened steel washer is fitted against the stabilizer bar link.
NOTE:
Use an additional wrench to prevent the ball joint rotating.
14. RH front: Connect the stabilizer bar link.
^ Install the washer.
^ Tighten the nut to 100 Nm (74 ft. lbs.).
NOTE:
Use an additional wrench to prevent the ball joint rotating.
15. RH front: Connect the suspension height sensor link arm.
^ Tighten the nut to 8 Nm (6 ft. lbs.).
16. Install the engine compartment LH heat shield.
^ Tighten the screws.
^ Tighten the nuts.
17. Install the front driveshaft.
18. Install the front wheels and tires.
^ Tighten the wheel nuts to 140 Nm (103 ft. lbs.).
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
19. Tighten the front lower arm nuts and bolts to 165 Nm (122 ft. lbs.), then tighten a further 90 degrees.
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.
20. Tighten the rear lower arm nuts and bolts to 165 Nm (122 ft. lbs.), then tighten a further 90 degrees.
21. RH front: Secure the air spring.
^ Tighten the nuts securing the air springs to 56 Nm (41 ft. lbs.).
22. Install the air cleaner assembly.
23. Install the engine cover.
24. Connect the hood support struts.
25. Connect the battery ground cable.
26. Check, and if necessary, adjust the wheel alignment.