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FRONT SUSPENSION
•
(7) Remove the shock absorber lower attaching n u t
and detach t h e stud f r o m the axle shaft tube bracket.
Remove t h e r e t a i n i n g n u t s and disconnect the stabi-
lizer b a r l i n k s from the spring brackets (Fig. 30).
(8) Disconnect the vacuum hoses from the shift mo-
t o r ports a n d t h e w i r e connector from 4 W D indicator
l a m p s w i t c h o n the shift motor housing.
(9) Remove nuts and t h e washers from t h e spring
U-bolts. Remove the complete front axle from the ve-
hicle.
INSTALLATION
(1) Position the front axle under the front o f the ve-
hicle w i t h t h e axle spring pads under t h e springs.
Place t h e s p r i n g brackets over t h e springs w i t h t h e
stabilizer b a r l i n k bolt holes facing toward the rear
of t h e vehicle (Fig. 30).
(2) I n s t a l l t h e spring U-bolts, washers and r e t a i n -
i n g n u t s . T i g h t e n the n u t s w i t h 149 N*m (110 ft-lbs)
torque.
(3) I n s e r t t h e shock absorber lower studs i n t h e
axle shaft tube brackets. I n s t a l l t h e attaching nuts
and t i g h t e n t h e m w i t h 75 N T H (55 ft-lbs) torque.
(4) Connect t h e stabilizer b a r l i n k s to t h e spring
brackets w i t h t h e bolts and n u t s (Fig. 30). T i g h t e n
the n u t s w i t h 271 N r n (200 ft-lbs) torque.
(5) Remove plugs and connect t h e brake hose fit-
tings. T i g h t e n the f i t t i n g s w i t h 9-17 N-m (80-150 i n -
lbs) torque.
(6) Connect the d r a g - l i n k b a l l stud to the steering
k n u c k l e a r m . I n s t a l l the r e t a i n i n g n u t and t i g h t e n i t
w i t h 8 1 N T H (60 ft-lbs) torque. To a l i g n t h e cotter
p i n hole i n the b a l l stud w i t h t h e slot i n the castel-
lated n u t ( i f the slot and t h e hole are n o t aligned),
continue to t i g h t e n t h e n u t u n t i l they are aligned.
Do not loosen the n u t to a l i g n the hole and the slot.
I n s t a l l a replacement cotter p i n .
(7) Connect the drive shaft to the drive p i n i o n gear
shaft
(axle) yoke w i t h
t h e i n s t a l l a t i o n reference
m a r k s aligned. I n s t a l l the washers and the n u t s and
t i g h t e n w i t h 34 N T H (300 in-lbs) torque.
(8) Connect t h e vacuum hoses to the shift motor
ports a n d t h e w i r e connector t o t h e 4 W D indicator
lamp s w i t c h .
(9) Remove the supports, lower the vehicle and re-
move t h e block from the brake pedal.
(10) Raise the vehicle, bleed and adjust the brakes,
lubricate a l l the b a l l stud f i t t i n g s , inspect the differ-
e n t i a l housing l u b r i c a n t level. Refer to the Specifica-
tions c h a r t .
(11) L o w e r t h e vehicle and test t h e axle and sus-
pension operation.
DIFFERENTIAL SERVICE
SERVICE
INFORMATION
I t i s n o t necessary t o remove t h e complete f r o n t
axle f r o m t h e vehicle for r o u t i n e axle or d i f f e r e n t i a l
service. To replace t h e differential side gears, i t i s
necessary t o remove only the axle shafts, t h e differ-
e n t i a l h o u s i n g cover, t h e l u b r i c a n t and the differen-
t i a l case. T o replace t h e differential bearings, i t is
necessary t o remove only t h e axle shafts, t h e differ-
e n t i a l h o u s i n g cover, t h e l u b r i c a n t , t h e d i f f e r e n t i a l
case and t o adjust the r i n g gear "backlash".
REMOVAL/DISASSEMBLY
(1) Raise a n d support the vehicle a t a comfortable
w o r k i n g h e i g h t .
(2) Remove t h e front wheels/tires.
(3) M a r k t h e f r o n t drive shaft and the d r i v e p i n i o n
gear shaft (axle) yoke for i n s t a l l a t i o n a l i g n m e n t ref-
erence.
(4) Disconnect t h e front drive shaft from t h e axle
yoke. A t t a c h t h e drive shaft t o t h e frame r a i l w i t h
w i r e .
(5) T h o r o u g h l y clean the outer area of the differen-
t i a l housing a n d axle shaft tubes w i t h an appropriate
cleaning solvent and blow d r y w i t h compressed air.
(6) Loosen t h e differential housing cover bolts and
d r a i n t h e l u b r i c a n t into a container. Remove t h e
bolts and t h e differential housing cover.
A c l o s e e x a m i n a t i o n o f t h e d i f f e r e n t i a l p r i o r t o
d i s a s s e m b l y
c a n o f t e n r e v e a l v a l u a b l e i n f o r m a -
t i o n c o n c e r n i n g t h e e x t e n t a n d t y p e o f r e p a i r s o r
a d j u s t m e n t s t h a t w i l l b e n e c e s s a r y . B e c a u s e t h e
m o s t f r e q u e n t causes o f a x l e n o i s e a r e i m p r o p e r
" b a c k l a s h " o r d i f f e r e n t i a l b e a r i n g " p r e l o a d " , o r
b o t h , a f e w m i n o r a d j u s t m e n t s c o u l d b e a l l t h a t
i s n e c e s s a r y t o c o r r e c t t h e d e f e c t .
Therefore, before disassembly, t h e f o l l o w i n g infor-
m a t i o n should be available:
• r i n g gear " b a c k l a s h " measurement,
• d r i v e p i n i o n gear shaft bearing "preload" torque
measurement, and
• r i n g gear/drive p i n i o n gear teeth contact patterns.
T h e r e s u l t s ( a b o v e ) s h o u l d b e r e c o r d e d a n d a n -
a l y z e d . I t i s e x p e c t e d t h a t t h e s e
m e a s u r e m e n t s
w i l l b e h e l p f u l w h e n m a k i n g n e c e s s a r y r e p a i r s
t o t h e d i f f e r e n t i a l . R e f e r t o t h e a p p l i c a b l e p r o c e -
d u r e s w i t h i n t h i s s e c t i o n f o r i n s t r u c t i o n s .
If, after t h e measurements
a n d adjustments, t h e
defect s t i l l exists, proceed w i t h t h e following disas-
sembly, inspection and assembly
procedures.
(7) T h o r o u g h l y
flush a n d clean t h e d i f f e r e n t i a l
gears, bearings and the other differential components
w i t h a n appropriate solvent.
(8) I n s t a l l a p i l o t stud i n t h e differential housing
and a t t a c h D i a l Indicator Tool C-3339 to t h e housing
(Fig. 31) w i t h the indicator plunger s l i g h t l y "loaded"
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