Front Differential Carrier Assembly Replacement (without F47)

Front Differential Carrier Assembly Replacement (without F47) Single Use Fasteners and Components Front Differential Carrier Bolt Front Differential Carrier Cover Gasket Front Differential Drive Pinion Gear Bearing Spacer Front Differential Drive Pinion Gear Nut Front Differential Drive Pinion Gear Seal Front Drive Axle Inner Shaft Retaining Ring Front Drive Axle Inner Shaft Seal Front Wheel Drive Shaft Nut [2x] Front Wheel Drive Shaft Retaining Ring [2x] Front Wheel Drive Shaft Seal [2x] Front Wheel Drive Shaft Slinger Special Tools Front Drive Axle DT-08614-20 Flange Retaining Bolts DT-22912-B Bearing Remover DT-24433 Pinion Cone and Side Bearing Installer DT-3289-20 Holding Fixture DT-35512 Inner Pinion Bearing Installer DT-38869 Rear Extension Seal Installer DT-45704 Pinion Bearing Race Installer - Dana 248 DT-52297 Front Axle Holding Fixture DT-52506 Pinion Flange Holder and Remover DT-52555 Side Bearing Installer DT-52556 Outer Pinion Bearing Cup Installer EN-45059-A Angle Meter EN-47966 Oil Control Valve Seal Remover GE-02619-A Slide Hammer w/Adapter GE-8092 Driver Handle Equivalent regional tools: Special Tools Front Suspension CH-42188-B Ball Joint Separator CH-43631 Ball Joint Separator Equivalent regional tools: Special Tools Wheel Drive Shafts DT-45859 Axle Remover Equivalent regional tools: Special Tools

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

Brake Dust Warning Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Front Differential Carrier Assembly Replacement (without F47) — figure 1

3. {without RC1} Remove the underbody skid shield: 3.1. Underbody Skid Shield Bolt (1) » Remove [4x] 3.2. Underbody Skid Shield (2) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 2

4. {with RC1} Remove the underbody skid shield: 4.1. Underbody Skid Shield Bolt (1) » Remove [2x] 4.2. Underbody Splash Shield Bolt (2) » Remove [2x] 4.3. Underbody Skid Shield (3) » Remove
5. Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation
6. Have an assistant apply the brakes.

Front Differential Carrier Assembly Replacement (without F47) — figure 3

Caution

DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

7. Front Wheel Drive Shaft Nut (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 4

Caution

DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

8. Front Wheel Drive Shaft Nut (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 5

9. Install the DT-45859 Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
10. Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
11. Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.

Front Differential Carrier Assembly Replacement (without F47) — figure 6

12. Front Brake Hose Bracket Bolt (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 7

13. Front Brake Caliper Bolt (2) » Remove [2x]

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

14. Remove the brake caliper and support with heavy mechanics wire. (1)

Front Differential Carrier Assembly Replacement (without F47) — figure 8

15. Front Wheel Speed Sensor Bolt (1) » Remove
16. Front Wheel Speed Sensor (2) » Remove
17. Front Wheel Speed Sensor Bracket Bolt (3) » Remove
18. Front Wheel Speed Sensor Bracket (4) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 9

19. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
20. Remove the front wheel speed sensor wiring harness bracket (2).

Front Differential Carrier Assembly Replacement (without F47) — figure 10

21. Steering Linkage Outer Tie Rod Nut (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 11

Caution

Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.

22. Using CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.

Note

Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.

23. Support the lower control arm with a suitable jack stand.

Front Differential Carrier Assembly Replacement (without F47) — figure 12

24. Front Stabilizer Shaft Link Nut (1) » Remove
25. Front Stabilizer Shaft Link @ Lower Control Arm » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 13

26. Front Upper Control Arm Ball Stud Nut (1) » Loosen

Front Differential Carrier Assembly Replacement (without F47) — figure 14

27. Using the CH-42188-B Ball Joint Separator (1), separate the right front upper control arm (2) from the steering knuckle.
28. Remove the CH-42188-B Ball Joint Separator (1) from the right front upper control arm (2) and the steering knuckle.

Front Differential Carrier Assembly Replacement (without F47) — figure 15

29. Front Upper Control Arm Ball Stud Nut (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 16

Caution

Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

Note

Some components not shown for graphic clarity.

30. Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.

Front Differential Carrier Assembly Replacement (without F47) — figure 17

Note

Some components not shown for graphic clarity.

31. Remove the front wheel drive half shaft (1) from the front axle.
32. Remove the front wheel drive half shaft (1) from the wheel hub.

Front Differential Carrier Assembly Replacement (without F47) — figure 18

33. Front Wheel Drive Shaft Retaining Ring (1) » Remove and DISCARD
34. Front Wheel Drive Shaft Seal (2) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 19

35. Install the DT-45859 Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
36. Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
37. Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.

Front Differential Carrier Assembly Replacement (without F47) — figure 20

38. Front Brake Hose Bracket Bolt (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 21

39. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 22

40. Front Brake Caliper Bolt (2) » Remove [2x]

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

41. Remove the brake caliper and support with heavy mechanics wire. (1)

Front Differential Carrier Assembly Replacement (without F47) — figure 23

42. Front Wheel Speed Sensor Bolt (1) » Remove
43. Front Wheel Speed Sensor (2) » Remove
44. Front Wheel Speed Sensor Bracket Bolt (3) » Remove
45. Front Wheel Speed Sensor Bracket (4) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 24

46. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
47. Remove the front wheel speed sensor wiring harness bracket (2).

Front Differential Carrier Assembly Replacement (without F47) — figure 25

48. Steering Linkage Outer Tie Rod Nut (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 26

Caution

Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.

49. Using CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.

Note

Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.

50. Support the lower control arm with a suitable jack stand.

Front Differential Carrier Assembly Replacement (without F47) — figure 27

51. Front Stabilizer Shaft Link Nut (1) » Remove
52. Front Stabilizer Shaft Link @ Lower Control Arm » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 28

53. Front Upper Control Arm Ball Stud Nut (1) » Loosen

Front Differential Carrier Assembly Replacement (without F47) — figure 29

54. Using the CH-42188-B Ball Joint Separator (1), separate the left front upper control arm (2) from the steering knuckle.
55. Remove the CH-42188-B Ball Joint Separator (1) from the left front upper control arm (2) and the steering knuckle.

Front Differential Carrier Assembly Replacement (without F47) — figure 30

56. Front Upper Control Arm Ball Stud Nut (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 31

Caution

Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

Note

Some components not shown for graphic clarity.

57. Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.

Front Differential Carrier Assembly Replacement (without F47) — figure 32

Note

Some components not shown for graphic clarity.

58. Remove the front wheel drive half shaft (1) from the front axle.

59. Remove the front wheel drive half shaft (1) from the wheel hub.

60. Front Wheel Drive Shaft Retaining Ring (1) » Remove and DISCARD

61. Front Wheel Drive Shaft Seal (2) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 33

62. { If equipped } Front Tire Front Air Deflector Bolt (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 34

Note

Quantity of fasteners may vary based on option content.

63. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Front Differential Carrier Assembly Replacement (without F47) — figure 35

Note

Quantity of fasteners may vary based on option content.

64. Front Wheelhouse Liner Bolt (1) » Remove [3x]
65. Front Wheelhouse Liner Retainer (2) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 36

Note

Quantity of fasteners may vary based on option content.

66. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Front Differential Carrier Assembly Replacement (without F47) — figure 37

Note

Quantity of fasteners may vary based on option content.

67. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Front Differential Carrier Assembly Replacement (without F47) — figure 38

68. Front Wheelhouse Liner (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 39

69. Unclip and reposition the chassis wiring harness bracket (1) away from the frame shock tower.

Front Differential Carrier Assembly Replacement (without F47) — figure 40

70. Front Shock Absorber Nut (1) » Remove [3x]

Front Differential Carrier Assembly Replacement (without F47) — figure 41

71. Front Shock Absorber Bolt (1) » Remove [2x]

Front Differential Carrier Assembly Replacement (without F47) — figure 42

72. {If Equipped} Disconnect the electrical connector at the shock absorber.
73. Front Shock Absorber (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 43

74. Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
75. Front Axle Propeller Shaft Bolt (2) » Remove [6x]
76. Front Axle Propeller Shaft Washer (3) » Remove [3x]
77. Front Axle Propeller Shaft » Reposition away

Front Differential Carrier Assembly Replacement (without F47) — figure 44

78. Disconnect the front drive axle actuator electrical connector (1).
79. Release the two harness retainers (2) and reposition harness.

Front Differential Carrier Assembly Replacement (without F47) — figure 45

Note

Some components not shown for graphic clarity.

80. { With L84, L87 } Electrical Connector @ Heater Coolant Pump (2) » Disconnect 80.1. Heater Water Auxiliary Pump Bolt (1) » Remove 80.2. Remove the heater coolant pump and heater water auxiliary pump bracket (2) as assembly and position aside.

Note

Ensure that the front axle is securely attached to the hydraulic jack.

81. Support the front axle with a hydraulic jack.

Front Differential Carrier Assembly Replacement (without F47) — figure 46

82. Front Differential Carrier Nut (1) » Remove
83. Front Differential Carrier Bolt (2) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 47

84. Drivetrain and Front Suspension Frame Reinforcement Nut (1) » Remove [4x]
85. Drivetrain and Front Suspension Frame Reinforcement Bolt (2) » Remove [4x]

Front Differential Carrier Assembly Replacement (without F47) — figure 48

86. Drivetrain and Front Suspension Frame Front Crossmember (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 49

87. Front Differential Carrier Bracket Nut (1) » Remove
88. Front Differential Carrier Bolt (2) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 50

89. Front Differential Carrier Bolt (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 51

90. Front Axle Vent Hose » Disconnect

Note

The front axle may have to be maneuvered to remove it from the vehicle.

91. Front Axle (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 52

92. Front Drive Axle Inner Shaft Housing Bolt (1) » Remove [4x]
93. Front Drive Axle Inner Shaft Housing (2) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 53

Note

Only 3 of the 4 mounting holes will be used to mount the axle service fixture.

94. Install the DT-52297 Front Axle Holding Fixture (2) to the front axle carrier using the front axle shaft tube mounting holes and attach to the DT-3289-20 Holding Fixture (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 54

95. Front Wheel Drive Shaft Slinger (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 55

96. Using EN-47966 Oil Control Valve Seal Remover (3) and GE-02619-A Slide Hammer w/Adapter (4), Remove the front wheel drive shaft (2).
97. Front Drive Axle Inner Shaft Retaining Ring (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 56

98. Using DT-52506 Pinion Flange Holder and Remover (1) with the DT-08614-20 Flange Retaining Bolts, Remove and DISCARD the front differential drive pinion gear nut (3).
99. Front Differential Drive Pinion Gear Washer (2) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 57

Note

Be careful not to damage the slinger when removing the pinion gear yoke assembly.

100. Using DT-52506 Pinion Flange Holder and Remover (2) with the DT-08614-20 Flange Retaining Bolts, Remove the front differential drive pinion gear yoke (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 58

101. Front Differential Drive Pinion Gear Seal (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 59

102. Front Differential Carrier Cover Bolt (3) » Remove [10x]
103. Front Differential Carrier Cover (2) » Remove
104. Front Differential Carrier Cover Gasket (1) » Remove and DISCARD

Front Differential Carrier Assembly Replacement (without F47) — figure 60

Note

Mark the location of the bearing caps with left and right. They must be installed in the original location.

105. Front Differential Bearing Cap Bolt (4) » Remove [4x]
106. Front Axle Hub Cap (3) » Remove [2x]
107. Front Differential Carrier Bearing Shim (2) » Remove [2x]
108. Front Differential (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 61

109. Front Differential Drive Pinion Gear (2) » Remove
110. Front Differential Drive Pinion Gear Bearing - Outer (1) » Remove

Front Differential Carrier Assembly Replacement (without F47) — figure 62

111. Front Differential Drive Pinion Gear Bearing Spacer (3) » Remove and DISCARD
112. Using DT-22912-B Bearing Remover (1) and shop press, Remove the differential drive pinion gear inner bearing (2).

Front Differential Carrier Assembly Replacement (without F47) — figure 63

113. Front Differential Carrier Vent Hose Connector (1) » Remove
114. Front Differential Carrier Shield Bolt (3) » Remove
115. Front Differential Drive Pinion Gear Lube Dam (2) » Remove
116. Remove the DT-52297 Front Axle Holding Fixture. Installation Procedure

Note

Only 3 of the 4 mounting holes will be used to mount the axle service fixture.

1. Install the DT-52297 Front Axle Holding Fixture (2) to the front axle carrier using the front axle shaft tube mounting holes and attach to the DT-3289-20 Holding Fixture (1).

2. Front Differential Drive Pinion Gear Lube Dam (2) » Install

Caution

Refer to Fastener Caution.

3. Front Differential Carrier Shield Bolt (3) » Install and tighten — Fastener Specifications
4. Front Differential Carrier Vent Hose Connector (1) » Install and tighten — Fastener Specifications

Front Differential Carrier Assembly Replacement (without F47) — figure 64

5. Using DT-52555 Side Bearing Installer (2) and GE-8092 Driver Handle (3), Install front drive axle inner shaft bearing (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 65

6. Using DT-38869 Rear Extension Seal Installer (2), Install NEW front drive axle inner shaft seal (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 66

7. Using DT-45704 Pinion Bearing Race Installer - Dana 248 (2) and GE-8092 Driver Handle (3), Install the differential drive pinion inner bearing cup (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 67

8. Using DT-52556 Outer Pinion Bearing Cup Installer (2) and GE-8092 Driver Handle (3), Install the differential drive pinion outer bearing cup (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 68

9. Measure the pinion shim thickness needed, refer to Pinion Depth Adjustment.
10. Install pinion shim onto pinion gear.
11. Using DT-24433 Pinion Cone and Side Bearing Installer (2), Install the differential drive pinion gear inner bearing (1).

Front Differential Carrier Assembly Replacement (without F47) — figure 69

12. Front Differential Drive Pinion Gear Bearing Spacer (1) » Install NEW

13. Front Differential Drive Pinion Gear Bearing - Outer (1) » Install

14. Front Differential Drive Pinion Gear (2) » Install

Front Differential Carrier Assembly Replacement (without F47) — figure 70

15. Using DT-38869 Rear Extension Seal Installer (2), Install NEW the front differential drive pinion gear seal (1).
16. Apply sealant to the pinion yoke splines. Adhesives, Fluids, Lubricants, and Sealers
17. Apply grease to the pinion seal where it will contact the pinion gear yoke slinger. Adhesives, Fluids, Lubricants, and Sealers

Front Differential Carrier Assembly Replacement (without F47) — figure 71

Note

Be careful not to damage the slinger when installing the pinion gear yoke assembly.

18. Front Differential Drive Pinion Gear Yoke (1) » Install

19. Front Differential Drive Pinion Gear Washer (2) » Install

Caution

Refer to Torque-to-Yield Fastener Caution.

20. Using DT-52506 Pinion Flange Holder and Remover (1) with the DT-08614-20 Flange Retaining Bolts, Install NEW front differential drive pinion gear nut (3) hand tight.

21. Tighten the front differential drive pinion gear nut (3) until there is no end play.

22. Measure the rotating torque of the pinion using an inch-pound torque wrench. Continue tightening the front differential drive pinion gear nut (3) until specified rotating torque is obtained, refer to Fastener Specifications.

23. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary.

24. Measure the differential bearing shim thickness needed, refer to Differential Carrier Bearing Preload Adjustment.

25. Measure and adjust the backlash, refer to Backlash Inspection and Adjustment.

26. Front Differential (1) » Install

27. Front Differential Carrier Bearing Shim (2) » Install [2x]

28. Front Axle Hub Cap (3) » Install [2x]

29. Front Differential Bearing Cap Bolt (4) » Install and tighten [4x] — Fastener Specifications

30. 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: 30.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 30.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 30.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 30.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

31. Front Differential Carrier Cover Gasket (1) » Install NEW

32. Front Differential Carrier Cover (2) » Install

33. Front Differential Carrier Cover Bolt (3) » Install and tighten [10x] — Fastener Specifications

Front Differential Carrier Assembly Replacement (without F47) — figure 72

34. Front Drive Axle Inner Shaft Retaining Ring (1) » Install NEW
35. Front Wheel Drive Shaft (2) » Install

Front Differential Carrier Assembly Replacement (without F47) — figure 73

36. Using DT-35512 Inner Pinion Bearing Installer (2), Install NEW front wheel drive shaft slinger  (1).

37. Remove the DT-52297 Front Axle Holding Fixture.

38. 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: 38.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 38.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 38.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 38.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

39. Front Drive Axle Inner Shaft Housing (2) » Install

40. Front Drive Axle Inner Shaft Housing Bolt (1) » Install and tighten [4x] — Fastener Specifications

Note

The front axle may have to be maneuvered to install it into the vehicle.

41. Front Axle (1) » Install
42. Front Axle Vent Hose » Connect

Caution

Refer to Fastener Caution.

43. Front Differential Carrier Bolt (1) » Install and tighten — Fastener Specifications

44. Front Differential Carrier Bolt (2) » Install

45. Front Differential Carrier Bracket Nut (1) » Install and tighten — Fastener Specifications

46. Drivetrain and Front Suspension Frame Front Crossmember (1) » Install

47. Drivetrain and Front Suspension Frame Reinforcement Bolt (2) » Install [4x]

48. Using the EN-45059-A Angle Meter, Install and tighten the 4 drivetrain and front suspension frame reinforcement nuts (1). Fastener Specifications

Caution

Refer to Torque-to-Yield Fastener Caution

49. Front Differential Carrier Bolt (2) » Install NEW
50. Front Differential Carrier Nut (1) » Install
51. Using the EN-45059-A Angle Meter, Tighten the front differential carrier nut (1). Fastener Specifications

Note

Some components not shown for graphic clarity.

52. { With L84, L87 } Install the heater coolant pump and heater water auxiliary pump bracket  (2) as assembly. 52.1. Heater Water Auxiliary Pump Bolt (1) » Install and tighten — Fastener Specifications 52.2. Electrical Connector @ Heater Coolant Pump (2) » Connect

53. Connect the front drive axle actuator electrical connector (1).

54. Reposition the harness and secure the two harness retainers (2).

55. Clean the residue from the threaded holes of the front differential drive pinion gear yoke with denatured alcohol and allow to dry.

56. 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: 56.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 56.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 56.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 56.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

57. Front Axle Propeller Shaft (1) » Reposition

58. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.

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

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

Note

Prior to installing the front shock absorber, you MUST apply anti-corrosion wax to the frame shock tower.

61. Apply anti-corrosion wax to the frame shock tower. Anti-Corrosion Treatment and Repair
62. Front Shock Absorber (1) » Install
63. {If Equipped} Connect the electrical connector at the shock absorber.

Note

Using a jack stand support the lower control arm to prevent over-articulation of the front lower control arm ball joint.

64. Front Shock Absorber Bolt (1) » Install and tighten [2x] — Fastener Specifications

65. Front Shock Absorber Nut (1) » Install and tighten [3x] — Fastener Specifications

66. Front Wheelhouse Liner (1) » Install

Note

Quantity of fasteners may vary based on option content.

67. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

Note

Quantity of fasteners may vary based on option content.

68. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

Note

Quantity of fasteners may vary based on option content.

69. Front Wheelhouse Liner Retainer (2) » Install
70. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

Note

Quantity of fasteners may vary based on option content.

71. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

72. { If equipped } Front Tire Front Air Deflector Bolt (1) » Install and tighten — Fastener Specifications

Front Differential Carrier Assembly Replacement (without F47) — figure 74

73. Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.

74. Front Wheel Drive Shaft Seal (2) » Install NEW

75. Front Wheel Drive Shaft Retaining Ring (1) » Install NEW

76. Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers

Note

Some components not shown for graphic clarity.

77. Install the front wheel drive half shaft (1) into the wheel hub.

78. Install the front wheel drive half shaft (1) into the front axle.

79. Ensure that the left front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.

80. Support the steering knuckle with a suitable jack stand.

81. Front Upper Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

82. Front Stabilizer Shaft Link @ Front Lower Control Arm » Install

83. Front Stabilizer Shaft Link Nut (1) » Install and tighten — Fastener Specifications

84. Steering Linkage Outer Tie Rod Nut (1) » Install and tighten — Fastener Specifications

85. Install the front wheel speed sensor wiring harness bracket (2).

86. Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

87. Front Wheel Speed Sensor (2) » Install

88. Front Wheel Speed Sensor Bolt (1) » Install and tighten — Fastener Specifications

89. Front Wheel Speed Sensor Bracket (4) » Install

90. Front Wheel Speed Sensor Bracket Bolt (3) » Install and tighten — Fastener Specifications

91. 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: 91.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 91.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 91.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 91.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

92. Front Brake Caliper (1) » Install

93. Front Brake Caliper Bolt (2) » Install and tighten [2x] — Fastener Specifications

94. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

95. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Install

96. Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.

97. Front Wheel Drive Shaft Seal (2) » Install NEW

98. Front Wheel Drive Shaft Retaining Ring (1) » Install NEW

99. Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers

Note

Some components not shown for graphic clarity.

100. Install the front wheel drive half shaft (1) into the wheel hub.

101. Install the front wheel drive half shaft (1) into the front axle.

102. Ensure that the right front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.

103. Support the steering knuckle with a suitable jack stand.

104. Front Upper Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

105. Front Stabilizer Shaft Link @ Lower Control Arm » Install

106. Front Stabilizer Shaft Link Nut (1) » Install and tighten — Fastener Specifications

107. Steering Linkage Outer Tie Rod Nut (1) » Install and tighten — Fastener Specifications

108. Install the front wheel speed sensor wiring harness bracket (2).

109. Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

110. Front Wheel Speed Sensor (2) » Install

111. Front Wheel Speed Sensor Bolt (1) » Install and tighten — Fastener Specifications

112. Front Wheel Speed Sensor Bracket (4) » Install

113. Front Wheel Speed Sensor Bracket Bolt (3) » Install and tighten — Fastener Specifications

114. 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: 114.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 114.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 114.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 114.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

115. Front Brake Caliper (1) » Install

116. Front Brake Caliper Bolt (2) » Install and tighten [2x] — Fastener Specifications

117. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

118. Have an assistant apply the brakes.

Caution

Refer to Torque-to-Yield Fastener Caution

119. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications

Caution

Refer to Torque-to-Yield Fastener Caution

120. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications
121. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation

Front Differential Carrier Assembly Replacement (without F47) — figure 75

122. Front Differential Carrier Oil Filler Plug (1) » Remove
123. Inspect the gear lubricant level, it should be 16–22 mm (0.6-0.9 in) below the plug opening.
124. If the level is low, add gear lubricant until the level is 16–22 mm (0.6-0.9 in) below the plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

125. Front Differential Carrier Oil Filler Plug (1) » Install and tighten — Fastener Specifications

126. {with RC1} Install the underbody skid shield: 126.1. Underbody Skid Shield (3) » Install 126.2. Underbody Splash Shield Bolt (2) » Install and tighten [2x] — Fastener Specifications 126.3. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

127. {Without RC1} Install the underbody skid shield: 127.1. Underbody Skid Shield (2) » Install 127.2. Underbody Skid Shield Bolt (1) » Install and tighten [4x] — Fastener Specifications

128. Remove the support and lower the vehicle.

129. Connect the battery negative cable.