Front axle. Pinion shaft seal

Front axle

REMOVAL

1) Raise and support the vehicle.

(2) Remove the skid plate, if equipped.

(3) Remove skid plate support crossmember, if necessary.

(4) Remove both C/V driveshafts.

(5) Mark the propeller shaft, transfer case, and pinion companion flange for installation alignment reference.

(6) Remove the front propeller shaft.

(7) Remove the axle vent tube.

(8) Use an adjustable and movable jack to support the differential housing.

(9) Remove bolts holding the axle to the engine mounts (Fig. 4).

(10) Remove bolts holding the axle to the pinion nose bracket (Fig. 5).

(11) Lower the jack and housing.

(12) Remove the axle from vehicle.

Fig. 4 Axle to Engine Mounts Mounting

1 - LEFT ENGINE MOUNT

2 - RIGHT ENGINE MOUNT

3 - FRONT AXLE

Fig. 5 Pinion Nose Bracket Mounting

1 - PINION NOSE BRACKET

2 - FRONT AXLE

INSTALLATION

(1) Raise the axle into position. Loosely install the bolts and nuts to hold the axle to the engine mounts and pinion nose bracket.

(2) Tighten all the bolts finger-tight, then tighten all bolts to 95 N*m (70 ft. lbs.).

(3) Install the axle vent tube.

(4) Align the reference marks on the propeller shaft, transfer case, and pinion companion flange.

(5) Install propeller shaft.

(6) Install the C/V driveshafts.

(7) Install the skid plate support crossmember, if necessary.

(8) Install the skid plate, if necessary.

(9) Check differential lubricant level and add lubricant, if necessary. Refer to Lubricant Specifications in this group for lubricant requirements.

(10) Remove the supports and lower the vehicle.

Pinion shaft seal

REMOVAL

(1) Raise and support the vehicle.

(2) Remove skid plate, if equipped.

(3) Remove both C/V driveshafts.

(4) Mark the propeller shaft and pinion companion flange for installation alignment reference.

(5) Remove the front propeller shaft.

(6) Rotate the pinion gear three or four times.

(7) Measure the amount of torque necessary to rotate the pinion with a (in. lbs.) dial-type torque wrench (Fig. 6). Record the torque reading for installation reference.

(8) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(9) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

(10) Hold the flange with Holder 6719. Remove the pinion nut.

(11) Remove the companion flange with Remover C-452 (Fig. 7).

(12) Using a suitable pry tool, or a slide hammer mounted screw, remove the pinion seal.

INSTALLATION

(1) Clean the seal contact surface in the housing bore.

(2) Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft.

(3) Inspect companion flange for cracks, worn splines and worn seal contact surface. Replace companion flange if necessary.

Fig. 6 Measure Total Axle Rotating Torque

1 - COMPANION FLANGE

2 - INCH POUND TORQUE WRENCH

Fig. 7 Companion Flange Removal

1 - COMPANION FLANGE

2 - PULLER TOOL

NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required.

(4) Apply a light coating of gear lubricant on the lip of pinion seal.

(5) Install seal with Installer C-3972-A and Handle C-4171 (Fig. 8).

Fig. 8 Pinion Seal Installation

1 - SPECIAL TOOL C-4171

2 - SPECIAL TOOL C-3972-A

(6) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(7) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

(8) Seat the companion flange on the pinion shaft with Installer C-3718 and Holder 6719.

(9) Remove the Installer C-3718 and install the new pinion nut.

CAUTION: Do not exceed the minimum tightening torque when installing the companion flange at this point. Damage to the collapsible spacer or bearings may result.

(10) Tighten the pinion nut until there is zero bearing end-play (Fig. 9).

(11) Tighten the nut to 271 N*m (200 ft. lbs.).

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

(12) Rotate the pinion shaft using a (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 N*m (5 in. lbs.) (Fig. 10).

(13) If the rotating torque is low, use Holder 6719 to hold the companion flange, and tighten the pinion nut in 6.8 N*m (5 ft. lbs.) increments until the proper rotating torque is achieved.

Fig. 9 Tighten Pinion Nut

1 - DIFFERENTIAL HOUSING

2 - COMPANION FLANGE HOLDER

3 - TORQUE WRENCH

Fig. 10 Check Pinion Rotation Torque

1 - COMPANION FLANGE

2 - INCH POUND TORQUE WRENCH

CAUTION: If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged.

Replace the collapsible spacer.

(14) Align the installation reference marks on the propeller shaft and companion flange and install the propeller shaft.

(15) Add gear lubricant to the differential housing, if necessary. Refer to the Lubricant Specifications for gear lubricant requirements.

(16) Install both C/V driveshafts.

(17) Install skid plate, if equipped.

(18) Lower the vehicle.