Driveshaft

Removal & Installation

Front 4WD

To Remove:

1. Put the vehicle in NEUTRAL then raise and safely support the vehicle.
2. Mark the alignment of the front axle pinion flange to the front driveshaft.
3. Mark the alignment of the transfer case pinion flange to the front driveshaft.
4. Remove the front driveshaft-to-transfer-case bolts and retainers.
5. Remove the front driveshaft-to-front-axle bolts.
6. Remove the front driveshaft.

To Install:

1. Install the driveshaft.
2. Install the front driveshaft-to-front-axle bolts. Torque to 11-15 ft-lb (15-20 Nm).
3. Install the front driveshaft-to-transfer-case bolts and retainers. Torque to 22 ft-lb (30 Nm).
4. Ensure correct alignment of the transfer case pinion flange to the front driveshaft using the marks made during removal.
5. Ensure the correct alignment of the front axle pinion flange to the front driveshaft.
6. Safely lower the vehicle.

Rear 4WD

To Remove:

1. Put vehicle in NEUTRAL the raise and safely support the vehicle.
2. Mark the alignment of the driveshaft flange to the rear axle pinion flange.

   Mark the alignment of the driveshaft flange to the rear axle pinion flange

3. Mark the alignment of the front flange and the transfer case flange.
4. Remove and throw away the 4 transfer case output flange-to-rear driveshaft flange bolts.
5. Remove and throw away the 4 rear axle flange bolts.

   CAUTION
   The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Using an appropriate tool, pry only in the area shown, to disconnect the driveshaft flange from the pinion flange.

6. Using an appropriate tool, pry only in the area shown. Separate the driveshaft flange from the rear axle pinion flange.

   Separate the driveshaft flange from the rear axle pinion flange

7. Lower the driveshaft from the vehicle.

To Install:

CAUTION
If new bolts are not available to fasten the driveshaft to the axle, coat the threads of the original bolts with the appropriate threadlock and sealer.

CAUTION
The driveshaft flange fits tightly on the rear axle pinion flange pilot. Tighten the bolts evenly in a cross pattern to ensure that the driveshaft flange sits squarely on the pinion flange.

1. Install the driveshaft into the vehicle.
2. Connect the driveshaft flange and the rear axle pinion flange using the alignment marks made during removal.
3. Install the 4 rear axle flange bolts. Torque to 83 ft-lb (112 Nm).
4. Install the 4 transfer case output flange-to-rear driveshaft flange bolts. Torque to 83 ft-lb (112 Nm).
5. Safely lower the vehicle.

Rear 2WD

To Remove:

1. Put the vehicle in NEUTRAL then raise and safely support the vehicle.
2. Mark the alignment of the driveshaft flange to the rear axle pinion flange.

   Mark the alignment of the driveshaft flange to the rear axle pinion flange

   NOTE: Be sure that the marks on the extension housing and driveshaft are aligned before separation.

   NOTE: Once the driveshaft has been removed, put an alignment mark on the transmission output shaft that matches the transmission extension housing mark.

3. Put an alignment mark on the driveshaft and extension housing.
4. Remove and throw away the 4 rear axle flange bolts.

   CAUTION
   The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Using an appropriate tool, pry only in the area shown, to disconnect the driveshaft flange from the pinion flange.

5. Using an appropriate tool, pry only in the area shown. Separate the driveshaft flange from the rear axle pinion flange.

   Separate the driveshaft flange from the rear axle pinion flange

6. Lower the driveshaft and slide it off the output shaft.
7. Plug the extension housing to prevent fluid loss.

To Install:

CAUTION
If new bolts are not available to fasten the driveshaft to the axle, coat the threads of the original bolts with the appropriate threadlock and sealer.

CAUTION
The driveshaft flange fits tightly on the rear axle pinion flange pilot. Tighten the bolts evenly in a cross pattern to ensure that the driveshaft flange sits squarely on the pinion flange.

1. Unplug the extension housing.
2. Raise the driveshaft and slide it into the output shaft.
3. Connect the driveshaft flange to the rear axle pinion flange.
4. Install the 4 rear axle flange bolts. Torque to 83 ft-lb (112 Nm).
5. Safely lower the vehicle.