REMOVAL & INSTALLATION
See Figure 1
- Raise the vehicle and support it safely on stands. Make certain the front stands will not interfere with the housing removal.
- Remove the under cover and drain the differential.
- Remove the hubs, knuckles and axle shafts as complete assemblies.
- Remove the inner shaft. Remove the circlip from the inner shaft and discard (a new one will be needed upon reassembly).
- Matchmark and remove the front driveshaft from the transfer case and the front differential.
- Support the differential housing with a jack.
- Remove the differential mounting brackets, make sure to note the locations of the removed bolts and nuts. The self-locking nuts will have to be replaced with new ones upon reassembly.
- Remove the front suspension crossmember. Use additional jacks or stands; the crossmember is heavy.
- Lower the differential housing and remove it from the vehicle.
- Mount the housing safely on a suitable jack and raise into position.
- Lubricate the bushings and install the crossmember and housing brackets. The crossmember mounting nuts and bolts should be tightened to 72-87 ft. lbs. (100-120 Nm). Tighten the housing bracket-to-differential bolts to 58-72 ft. lbs. (80-100 Nm) and the housing brackets-to-frame mounting self locking nuts and bolts to 58-80 ft. lbs. (80-110 Nm). It is important that new self locking nuts are used during installation.
- Replace the circlips and install the inner axle and axle, knuckle and hub assemblies.
- Install the front driveshaft-refer to the previous procedures.
- Tighten the drain plug to 43-51 ft. lbs. (60-70 Nm). Level the vehicle and fill the differential with gear until it just starts to spill out of the fill hole. Tighten the fill plug to 29-43 ft. lbs. (40-60 Nm).
- Install the under cover and tighten the under cover mounting bolts to 7-9 ft. lbs. (10-13 Nm). Lower the vehicle.
- Perform a road test and check the differential for leaks.