Front Axle Propeller Shaft Replacement (L84, L87)

Single Use Fasteners and Components Transfer Case Front Output Shaft Boot Clamp Special Tools DT-35910 Drive Axle Seal Clamp Pliers Equivalent regional tools: Special Tools

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury. Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle

Front Axle Propeller Shaft Replacement (L84, L87) — figure 1

2. Disconnect the heated oxygen sensor electrical connector.

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution.

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

3. Remove the heated oxygen sensor  (1) using a suitable tool.
4. { If equipped } Transfer Case Skid Shield » Remove — Transfer Case Skid Shield Replacement

Front Axle Propeller Shaft Replacement (L84, L87) — figure 2

5. Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft » Remove and DISCARD

Front Axle Propeller Shaft Replacement (L84, L87) — figure 3

6. Front Axle Propeller Shaft Bolt (2) » Remove [6x]
7. Front Axle Propeller Shaft Washer (3) » Remove [3x]

Front Axle Propeller Shaft Replacement (L84, L87) — figure 4

8. Front Axle Propeller Shaft (1) » Remove Installation Procedure

Front Axle Propeller Shaft Replacement (L84, L87) — figure 5

1. Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers

2. Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.

3. Front Axle Propeller Shaft (3) » Install

4. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 4.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 4.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 4.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 4.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

5. Front Axle Propeller Shaft Washer (3) » Install [3x]

Caution

Refer to Fastener Caution.

6. Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications

Front Axle Propeller Shaft Replacement (L84, L87) — figure 6

7. Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the front axle propeller shaft.
8. Using the DT-35910 Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
9. { If equipped } Transfer Case Skid Shield » Install — Transfer Case Skid Shield Replacement

Caution

Refer to Component Fastener Tightening Caution.

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

10. Install and tighten the heated oxygen sensor  (1) using a suitable tool. Fastener Specifications
11. Connect the heated oxygen sensor electrical connector.
12. Remove the support and lower the vehicle.