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FRONT SUSPENSION
2 - 61
(4) Remove plugs and connect t h e brake hose f i t -
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.
(5) Connect the d r a g - l i n k b a l l stud t o 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«m (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 t h e castel-
lated n u t ( i f the slot and t h e hole are n o t aligned),
continue t o t i g h t e n t h e n u t u n t i l t h e y are aligned.
Do not loosen the n u t t o a l i g n t h e hole a n d t h e slot.
I n s t a l l a replacement cotter p i n .
(6) Connect the drive shaft t o the d r i v e 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 a n d the n u t s and
t i g h t e n w i t h 34 N n n (300 in-lbs) torque.
(7) Remove the supports, lower the vehicle a n d re-
move the block from the brake pedal.
(8) Raise t h e vehicle, bleed and adjust the brakes,
l u b r i c a t e a l l the b a l l stud f i t t i n g s , inspect t h e differ-
e n t i a l housing l u b r i c a n t level. Refer t o the Specifica-
tions chart.
(9) Lower t h e vehicle and test t h e axle a n d front
suspension operation.
DIFFERENTIAL SERVICE
SERVICE
INFORMATION
I t is 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 differential
service. To replace t h e differential side gears, i t is
necessary t o remove only the axle shafts, t h e differ-
e n t i a l housing cover, the l u b r i c a n t and the differen-
t i a l case. To replace t h e differential bearings, i t is
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 , t h e differential
case and t o adjust the r i n g gear "backlash".
REMOVAL/DISASSEMBLY
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height.
(2) Remove the f r o n t wheels/tires.
(3) M a r k t h e front drive shaft and the drive 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 f r o n t 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 o f the differen-
t i a l housing and axle shaft tubes w i t h a n appropriate
cleaning solvent and blow dry 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 i n t o 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 "
t o r q u e , 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 a 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 "backlash" measurement,
• drive p i n i o n gear shaft b e a r i n g " p r e l o a d " torque
measurement, and
• r i n g gear/drive p i n i o n gear t e e t h contact patterns.
T h e r e s u l t s (above) 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 f o l l o w i n g disas-
sembly, inspection and assembly procedures.
(7) Thoroughly
flush a n d clean t h e differential
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 h o u s i n g
and attach D i a l Indicator Tool C-3339 t o the h o u s i n g
(Fig. 20) w i t h the indicator plunger s l i g h t l y "loaded"
and a t a r i g h t angle (i.e., perpendicular) to the back
side o f t h e r i n g gear. "Zero" t h e d i a l
indicator
pointer.
DIAL INDICATOR
Fig. 20 Ring Gear "Runout" Measurement
(9) Measure the r i n g gear " r u n o u t " b y r o t a t i n g t h e
r i n g gear several complete revolutions and observing
the d i a l indicator pointer. M a r k b o t h t h e r i n g gear
and t h e differential case flange a t t h e location o f
m a x i m u m " r u n o u t " .
T h e m a r k o n t h e d i f f e r e n t i a l case f l a n g e w i l l
b e v e r y u s e f u l w h e n m e a s u r i n g t h e d i f f e r e n t i a l
case
" r u n o u t " . T h e d i f f e r e n t i a l
case
f l a n g e
" r u n o u t " m e a s u r e m e n t
p r o c e d u r e
i s
d e s c r i b e d
b e l o w .
I f t h e c o m b i n e d r i n g g e a r " r u n o u t " (i.e., p e a k -
t o - p e a k ) exceeds o f 0.006 i n c h (0.150 m m ) , p o s s i -
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