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FRONT SUSPENSION
2 - 23
(16) Remove t h e differential housing coyer screws
and the cover. D r a i n t h e l u b r i c a n t into a clean con-
tainer.
(17) Force t h e i n n e r axle shaft t o w a r d the center of
t h e vehicle a n d remove t h e " C " lock f r o m t h e re-
cessed groove i n the shaft.
(18) Use Tool D-354-4 and A d a p t o r Tool D-354-3 to
remove the i n n e r axle shaft (Fig. 18).
Fig. 18 Inner Axle Shaft Removal/Installation
(19) Use Tool D-354-4, Tool D-354-1, a n d Puller
Tool C-637 t o remove t h e i n n e r axle shaft bearing
(Figs. 16 and 18).
ASSEMBL
Y/INSTALLA
TION
(1) Use Tool D-354-4, Tool 354-2 and Tool C-637 to
i n s t a l l the i n n e r axle shaft b e a r i n g (Figs. 16 and 18).
(2) Insert t h e i n n e r axle shaft i n t o t h e axle shaft
tube w i t h Tool D-354-4 a n d Adaptor Tool
D-354-3
(Fig. 18). Carefully slide t h e axle shaft i n t h e side
gear and i n s t a l l t h e " C " lock i n t h e axle shaft re-
cessed groove.
(3) Inspect the i n n e r axle shaft seal contact surface
and remove a n y m a t e r i a l t h a t could have remained
i n the axle shaft tube bore after t h e o r i g i n a l seal was
removed. Clean t h e outer axle shaft tube bore w i t h
crocus cloth a n d remove t h e r u s t from t h e area
where the seal i n s t a l l a t i o n tool w i l l be located.
(4) I n s t a l l t h e replacement axle shaft seal on Tool
5041-1 and position i t i n the s h i f t motor housing. I n -
sert Threaded
B a r Tool
5041-2 t h r o u g h t h e seal
t h r e a d i t i n t o Tool 5041-1. I n s t a l l Tool 5041-3 and
t h e r e t a i n i n g n u t on the end o f t h e threaded bar tool
and t i g h t e n t h e n u t u n t i l t h e tool contacts t h e
threaded bar shoulder.
(5) I n s t a l l t h e shift collar o n t h e splined end of the
i n n e r axle shaft.
(6) I n s t a l l t h e needle bearing i n the end of the i n -
termediate shaft w i t h Tool D-328 and Handle Tool C-
4171 (Fig. 19).
UK 727
Fig. 19 Intermediate Shaft Bearing Installation
(7) Lubricate t h e splined end of the i n t e r m e d i a t e
axle shaft w i t h a l i b e r a l amount of multi-purpose l u -
bricant and insert i t t h r o u g h inner axle shaft seal.
Use c a r e t o a v o i d d a m a g i n g t h e seal.
(8) I n s t a l l t h e shift motor housing gasket a n d
cover. E n s u r e
t h a t t h e s h i f t f o r k i s c o r r e c t l y
g u i d e d i n t o t h e s h i f t c o l l a r g r o o v e .
(9) I n s t a l l t h e shift motor housing cover shield a n d
bolts. T i g h t e n t h e bolts w i t h
14 N - m (10 ft-lbs)
torque.
(10) Connect t h e v a c u u m hoses to t h e shift motor
ports and t h e w i r e connector t o the 4 W D indicator
switch. W r a p t h e r e t a i n i n g clip securely a r o u n d t h e
4 W D indicator switch connector.
(11) I n s t a l l t h e splash shield and t h e spindle. I n -
stall the washers and replacement nuts. T i g h t e n t h e
nuts w i t h 34-41 N n n (25-30 ft-lbs) torque.
(12) Position t h e rotor/hub a n d t h e outer
wheel
bearing on t h e spindle.
(13) I n s t a l l t h e adjusting n u t and, u s i n g Tool C-
4170, t i g h t e n i t w i t h 68 N«m (50 ft-lbs) torque t o
"seat" the wheel bearings. Loosen adjusting n u t and
re-tighten i t w i t h 41-54 N i n (30-40 ft-lbs) torque
w h i l e r o t a t i n g rotor/hub. Loosen the adjusting n u t
135° to 150°. Position the r e t a i n i n g washer on the ad-
j u s t i n g n u t b y r o t a t i n g the n u t so t h a t the a l i g n m e n t
p i n pressed i n t o t h e n u t w i l l enter the nearest hole
i n the r e t a i n i n g washer. I n s t a l l and t i g h t e n the n u t
lock w i t h 68 N»m (50 ft-lbs) torque. The wheel bear-
i n g "end p l a y " after t h e f i n a l bearing adjustment
should be w i t h i n 0.001 i n c h to 0.010 i n c h (0.03 t o
0.25 m m ) .
(14) I n s t a l l t h e r e t a i n i n g spring, t h e d r i v i n g h u b
and the r e t a i n i n g r i n g .
(15) A p p l y R T V sealant to the sealing edge of t h e
dust cap and i n s t a l l i t on the hub.
(16) Position t h e inboard brake pad on t h e brake
caliper adapter w i t h t h e pad flanges engaged w i t h
the adapter r a i l s . Slowly slide t h e caliper into posi-
t i o n i n t h e adapter and over t h e brake rotor. A l i g n
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