Front Drive Axle/Differential
Axle Assembly
Special Service Tools
Ball joint separator
205-754(LRT-54-027)
Front Stabilizer Bar Bushing Tightening Tool
204-703
Front Stabilizer Bar Bushing Tightening Tool
204-705
Removal
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
All vehicles
1
WARNING: Make sure to support the vehicle with axle stands.
Raise and support the vehicle.
2 Remove the front wheels and tires.
3 Remove the axle tube. For additional information, refer to Axle Tube Service and Repair
4 Remove the LH splash shield.
- Remove the 4 clips.
5 Release the LH stabilizer bar link.
- Remove and discard the nut.
6 Release the LH brake hose bracket from the wheel knuckle.
- Remove the bolt.
7
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
Using the special tool, release the LH tie-rod end ball joint from the wheel knuckle.
- Remove and discard the nut.
8
CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to the premature failure of the joint.
CAUTION: The lower arm ball joint can be damaged by excessive articulation. The wheel knuckle must be fully supported at all times. Do not allow the wheel knuckle to hang on the lower arm. Failure to follow this instruction will result in damage to vehicle.
Using the special tool, release the LH upper arm ball joint.
- Remove and discard the nut.
9 Release the LH halfshaft from the axle assembly.
- Remove and discard the snap ring.
- Using a suitable tie strap, support the LH halfshaft.
10
CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
Release the driveshaft from the front axle drive flange.
- Remove the 6 Torx bolts and washers, discard the bolts.
- Using a suitable tie strap, secure the driveshaft end plate.
Vehicles with Active Stabilization
11 Remove the stabilizer bar bushing.
- Remove the 3 bolts.
- Remove the clamp.
- Remove the stabilizer bar bushing.
Vehicles with diesel engine
12 Release the fuel cooler.
- Remove the bolt.
Vehicles with 5.0L engine
13 Release the automatic transmission fluid cooler.
- Remove the 4 bolts.
14 Remove the transmission fluid cooler mounting bracket.
- Release the transmission fluid cooler pipe bracket.
- Remove the nut.
- Remove the 3 bolts.
All vehicles
15 Remove the front axle crossmember.
- Remove the 4 bolts.
16
CAUTION: Before the disconnection or removal of any components, make sure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.
Disconnect the breather line.
- Release the clip.
17 Using a transmission jack, support the front axle assembly.
18 With assistance, remove the front axle assembly.
- Remove and discard the 3 axle assembly rear mounting bolts.
- Remove the front axle assembly front mounting bolt.
Installation
All vehicles
1 With assistance, install the front axle assembly.
- With assistance, raise and manoeuvre the front final drive unit.
- Tighten the 3 new bolts in the front axle assembly to 80 Nm (59 lb.ft), then a further 60 degrees.
- Tighten the front axle assembly front mounting bolt to 105 Nm (77 lb.ft).
2 Connect the breather line.
3 Install the front axle crossmember.
- Tighten the 4 bolts to 115 Nm (85 lb.ft).
Vehicles with 5.0L engine
4 Install the transmission fluid cooler mounting bracket.
- Tighten the 3 bolts to 25 Nm (18 lb.ft.).
- Secure the transmission fluid cooler coolant pipe to the coolant hose bracket.
- Tighten the nut to 15 Nm (11 lb.ft).
5 Install the automatic transmission fluid cooler.
- Tighten the 4 bolts to 25 Nm (18 lb.ft.).
Vehicles with diesel engine
6 Secure the fuel cooler.
- Tighten the bolt to 23 Nm (17 lb.ft).
Vehicles with Active Stabilization
7 Install the stabilizer bar bushing.
- Install the clamp.
- Install the bolts.
- Tighten the bolts to 115 Nm (85 lb.ft).
All vehicles
8
NOTE:
Make sure that new bolts are installed.
Secure the driveshaft to the front axle drive flange.
- Stage 1: Tighten the bolts to 45 Nm (33 lb.ft).
- Stage 2: Tighten the bolts a further 90 degrees.
- Remove and discard the tie strap.
9 Install a new snap ring to the LH halfshaft.
- Remove and discard the tie strap.
10
NOTE:
Do not fully engage the halfshaft until the oil seal protector has been removed.
Secure the LH halfshaft in the axle assembly.
1) Open the halfshaft seal protector and install the halfshaft.
2) Release the halfshaft seal protector from the halfshaft seal.
3) Remove the halfshaft seal protector.
4) Fully install the halfshaft.
11
WARNING: Make sure that a new nut is installed.
Secure the LH upper arm to the wheel knuckle.
- Install a new nut and tighten to 70 Nm (52 lb.ft).
12
WARNING: Make sure that a new nut is installed.
Secure the LH tie-rod end ball joint to the wheel knuckle.
- Install a new nut and tighten to 70 Nm (52 lb.ft).
13 Secure the LH brake hose bracket to the wheel knuckle.
- Tighten the bolt to 22 Nm (16 lb.ft).
14 Secure the LH stabilizer bar link.
- Install a new nut and tighten to 115 Nm (85 lb.ft).
15 Install the LH splash shield.
- Install the clips.
16 Install the axle tube. For additional information, refer to Axle Tube Service and Repair
17 Install the wheels and tires.
- Tighten the wheel nuts to 140 Nm (103 lb.ft).