REMOVAL & INSTALLATION
Navajo and 1994-97 B Series Pick-up Models
See Figures 1, 2 and 3
- Loosen the front wheel lug nuts.
- Raise and support the vehicle safely. Remove the wheel and tire assembly.
- Remove the disc brake calipers and support the caliper on the vehicle's frame rail.
- Remove the hub locks and lock nuts.
- Remove the hub and rotor.
- Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or rawhide hammer to jar the spindle from the knuckle.
- Remove the front disc brake rotor shield.
The left-hand axle shaft is engaged inside of the front carrier assembly. Depending on how the truck is sitting (especially if it is not level), some fluid may leak out of the front carrier assembly. A small drip pan should can be placed underneath the front carrier as a precautionary measure.
- Remove the left-hand side axle shaft by pulling the assembly out of the carrier and through the hole in the steering knuckle (spindle mount).
Remove the right-hand axle shaft by performing the following:
- Remove and discard the right front axle joint boot clamp from the outer axle assembly.
- Pull the right-hand axle shaft out of the axle joint boot and stub shaft and through the hole in the steering knuckle (spindle mount).
Inspect the seals on the outer axle shaft ends, and replace them if necessary. Replace the seals as follows:
- Remove the old seal from the axle shaft by driving them off with a hammer.
- Thoroughly clean the axle seal area of the shaft.
- Place the shaft in a press and install the new seal using the Spindle/Axle Seal Installer Tool T83T-3132-A, or equivalent.
Install the right-hand axle shaft as follows:
- Ensure that the rubber boot is properly installed on the carrier stub shaft. Slide a new outer axle shaft boot clamp onto the rubber boot.The model 35 front axle does not use blind, or master, splines. Therefore, special attention should be made to ensure that the yoke ears are in line (in phase) during assembly.
- Slide the right axle shaft assemble through the hole in the steering knuckle, into the rubber boot and engage the splines of the stub shaft. Ensure the splines are fully engaged.
- Position the rubber boot and clamp onto the outer axle shaft and crimp the clamp securely on the rubber boot using Keystone Clamp Pliers T63P-9171-A.
- Install the left-hand axle shaft by sliding it through the hole in the steering knuckle and engaging it into the carrier. Ensure that the shaft is fully seated into the carrier and engage to the splines inside.
- Install the front disc brake rotor shield, spindle and retaining nuts.
- Install the front brake rotors, bearings, locknuts and hubs.
- Install the brake caliper and wheel assembly.
- Lower the vehicle. Tighten the lug nuts to specification.
See Figures 4, 5, 6, 7 and 8
- Loosen the front wheel lug nuts.
- Raise and safely support the vehicle.
- Remove the wheels.
- Remove and discard the center wheel hub nut and washer.
- Remove the disc brake caliper and position it aside.
The hub shaft is a slip fit into the wheel hub and bearing; a press is not normally required.
- Ensure that the wheel hub shaft can be pushed inwards. If not, assemble a press to the front wheel studs and press the wheel hub shaft inwards slightly to break it loose.
- Place a jack under the lower control arm to support it.
- Remove the upper ball joint-to-steering knuckle retaining bolt and separate the joint from the knuckle.
- Remove the outboard CV-joint from the wheel hub by slightly rotating the steering knuckle down, taking care not to overstress the joint or boot, and pulling the CV-joint out from the hub.
- Use a CV-joint puller and impact slide hammer to pull the inboard CV-joint from the axle housing. You can also use a prytool to carefully pry the CV-joint outward to disengage the internal circlip. Take care to not damage the axle housing seal.
- Remove the halfshaft from the vehicle. Remove the circlip from the inboard CV-joint end and discard it.
- Install a new circlip to the inboard CV-joint end.
- Position the halfshaft into the vehicle. Slide the inboard CV-joint end into the axle housing until it is fully seated. Ensure that the circlip is engaged in the housing by attempting to pull the joint outwards.
- Install the outboard CV-joint end into the wheel hub.
- Position the upper ball joint to the steering knuckle and install the retaining bolt.
- Install the disc brake caliper back onto the rotor.
- Install a new wheel hub nut and washer and tighten to 157-213 ft. lbs. (212-288 Nm).
- Install the wheel and lug nuts.
- Lower the vehicle and tighten the lug nuts.
See Figure 9
- Raise and safely support the vehicle. Remove the wheel and tire assembly.
- Remove and discard the halfshaft locknut.
- Disconnect the tie rod end from the knuckle.
- Remove the caliper and brake rotor from the knuckle. Support the caliper aside with rope or mechanics wire; do not let it hang by the brake hose.
- Remove the nut and bolts and remove the lower ball joint. Remove the bolts and nuts and remove the knuckle/hub assembly from the strut.
If the halfshaft is stuck to the hub, install a used locknut so it is flush with the end of the shaft, then tap the nut with a soft mallet.
- Remove the splash shield.
- Using a suitable prybar, pry out the halfshaft from the differential and remove the halfshaft from the vehicle. Be careful not to damage the dust cover or oil seal.
- Install a new clip on the halfshaft. Coat the differential seal with clean transmission fluid.
- Install the halfshaft in the differential, being careful not to damage the seal. After installation, attempt to pull the halfshaft outward to make sure it does not come out.
- Install the knuckle/hub assembly to the strut and tighten the nuts to 69-86 ft. lbs. (93-117 Nm).
- Install the lower ball joint. Tighten the bolts to 75-101 ft. lbs. (102-137 Nm) and the nut to 115-137 ft. lbs. (157-187 Nm). Install a new cotter pin.
- Install the brake rotor and caliper.
- Connect the tie rod end to the knuckle.
- Install a new locknut and tighten to 174-231 ft. lbs. (235-314 Nm). After tightening, stake the locknut using a blunt chisel.
- Install the splash shield. Install the wheel and tire assembly and lower the vehicle.
- Check the front end alignment.