REMOVAL & INSTALLATION
See Figures 1 through 11
This procedure only applies to the 4WD models.
- Raise and safely support the vehicle.
- Remove the wheel and tire assembly.
- Remove the cotter pin and lock cap from the halfshaft.
- While applying the brakes, remove the locknut from the halfshaft.
- Remove the cotter pin and locknut to the tie rod end and disconnect the tie rod end from the knuckle.
- Remove the lower ball joint bolts from the steering knuckle.
- Place matchmarks on the halfshaft and side gear. Remove the six bolts from the inner halfshaft joint and disconnect the halfshaft from the side gear.
- Remove the halfshaft by pulling the control arm down and extracting the halfshaft from the wheel hub. On models with ABS, make sure not to damage the ABS rotor.
If the outer shaft will not come out of the hub, soak the splines with penetrating lube, install the nut and tap on the halfshaft with a rubber hammer. Be careful not to damage the shaft threads.
Coat the halfshaft splines with anti-seize compound to prevent spline seizure. This will help for future halfshaft removal.
- Insert the halfshaft into position.
- Connect the halfshaft to the steering knuckle.
- Connect the inner halfshaft joint to the side gear and tighten the six bolts to 51 ft. lbs. (61 Nm).
- Connect the lower ball joint, then tighten the bolts to 94 ft. lbs. (127 Nm).
- Install the tie rod end, tighten the nut to 36 ft. lbs. (49 Nm) and insert a new cotter pin.
- Install the halfshaft nut.
While a helper is applying the brakes, tighten the drive shaft locknut to:
1991-137 ft lbs. (186 Nm)
- Install the lock cap and new cotter pin.
- On models with a ABS speed sensor, secure the sensor to 69 inch lbs. (8 Nm).
- Install the front wheel, hand tighten the lugnuts and lower the vehicle.
- tighten the lugnuts to specifications.
- Check the front end alignment.
See Figures 12 through 17
- Remove the halfshaft.
- Remove the inboard joint boot clamps.
- Clean the joint before removing the boot.
- Slide the inboard joint boot toward the outboard joint.
- Place matchmarks on the inboard joint tulip and the shaft. Remove the inboard joint tulip from the driveshaft.
- Clamp the driveshaft in a vise. Using a snapring expander, remove the snapring and disassemble the tripod joint.
- Using a brass bar and hammer, remove the tripod joint from the driveshaft. Do not punch the roller.
- Remove the inboard joint boot.
- Remove the outboard joint boot clamps and boot. Do not disassemble the outboard joint.
- Temporarily install the new boot and new boot clamps to the outboard joint.
Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot.
- Temporarily install the new boot and the new boot clamps for the inboard joint to the driveshaft.
Assemble the tripod joint.
- Place the beveled side of the tripod axial spline toward the outboard joint.
- Align the matchmarks placed before disassembly.
- Using a brass bar and hammer, tap in the tripod joint onto the driveshaft. Do not punch the roller.
- Using a snap ring expander, install a new snapring.
- Before assembling the boot to the outboard joint, pack the boot with grease. Usual capacity is 4.2-4.6 oz. (120-130 g).
Keep the grease off the joint connection groove of the boot. Pack in grease all over the ball and contact surface inside the joint.
- Assemble the inboard joint to the inboard joint tulip. Pack in grease to the inboard tulip and the boot. Usual capacity is 7.6-7.9 oz. (215-225 g).
- Align the matchmarks on the outer race and shaft, then install the outer race.
- Install the boot to the inboard joint.
Be sure the boot is on the shaft groove and inboard joint outer race groove. Install the boot without twisting it.
Set the length of the shaft to the following:
1991 models-19.41-19.81 inch (493-502mm)
- Insatall the two clamps to the inboard joint boot. Bend back the band and lock it.
- Install the halfshaft.