Replace Front Axle Pinion Bushing

Part Number 1L2Z-3A443-BA

1. Raise vehicle on a hoist suitable for access to the front drive axle assembly.

2. Remove the front frame crossmember (4 bolts).

3. Disconnect front suspension stabilizer bar at the frame clamps (4 bolts) and link bolts (2 bolts), drop bar and allow it to rest on the lower suspension "A" arms.

4. Support axle with jack stand or transmission jack.

NOTE
DAMAGE TO CV JOINT BOOTS CAN OCCUR IF AXLE ASSEMBLY IS ALLOWED TO REST ON THE BOOTS.

WARNING
SECURE THE AXLE TO THE JACK WITH A SAFETY STRAP. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.





5. Remove the three axle attachment bolts at the isolation bushings, allow the axle to drop out of the frame brackets, and roll the pinion nose down for access to the Pinion Bushing. (Figure 2).

CAUTION
ANYTIME BOLTS, WASHERS, SPACERS, OR NUTS ARE LOOSENED IN THE FRONT DIFFERENTIAL SUPPORT FOR ANY REASON, INSTALL NEW COMPONENTS TO PREVENT DAMAGE.





6. Note the indexing and flange depth of the current Pinion Bushing and remove it using the following tools: Figure 3.

^ 205-376

^ 205-371

^ 205-374

7. Install the new Pinion Bushing using the same rotational indexing and depth as the original bushing with the following tools: Figure 4.

^ 204-187

^ 205-369

^ 205-374

8. Using all new hardware, reinstall the axle, stabilizer bar, and the crossmember by reversing Steps 1 through 5. The stabilizer link bolts must be tightened while the vehicle is resting on the tires with the suspension in the normal curb height condition.





CAUTION
THE CAN (DOMED CV JOINT HOUSING COVER) ON THE FRONT DRIVESHAFT IS PRESSED INTO THE CV JOINT HOUSING AT THE FACTORY WHEN HOUSED CORRECTLY, THE CAN WILL APPEAR AS SHOWN IN FIGURE 1, "TOP BOX". DO NOT RESEAT THE CAN IN THE CV JOINT HOUSING IF THE CAN'S FLANGE IS ABOVE THE CV JOINT HOUSINGS SHOWN IN FIGURE 1, "BOTTOM BOX", INSTALL A NEW DRIVESHAFT.

9. Verify that the can flange is housed correctly in the CV joint housing as shown in Figure 1, top box. Install a new driveshaft if the can flange is not housed correctly.

CAUTION
ALWAYS CONNECT THE FRONT DRIVESHAFT TO THE AXLE FIRST. OTHERWISE THE WEIGHT OF THE DRIVESHAFT CAN PINCH THE BOOT BETWEEN THE SHAFT AND HOUSING AND CAN CAUSE THE BOOT TO TEAR.

NOTE
ALIGN THE INDEX MARKS.

10. Install the front driveshaft.

CAUTION
TIGHTEN THE BOLTS EVENLY IN A CROSS PATTERN OR DAMAGE WILL OCCUR TO THE CV JOINT.

NOTE
INSTALL NEW WASHERS AND BOLTS. IF NEW BOLTS ARE NOT AVAILABLE, COAT THE THREADS OF THE ORIGINAL BOLTS WITH THREADLOCK AND SEALER.

11. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern.

12. Verity that the CV joint has seated squarely in the transfer case flange.

a. Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the two components.

b. Rotate the driveshaft 1/4 turn.

c. Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top of the bottom of the two components.

d. Repeat this procedure several times.

e. If the space is not equal at any point in the attachment, remove and reinstall the driveshaft as described in this procedure.

NOTE
INSTALL NEW UNIVERSAL JOINT RETAINERS AND BOLTS. IF NEW BOLTS ARE NOT AVAILABLE, COAT THE THREADS OF THE ORIGINAL BOLTS WITH THREADLOCK AND SEALER.

13. Install the new universal joint retainer and bolts.

14. Install the skid plate, if equipped.