Axle Housing Assembly (Differential)

Removal & Installation

To Remove:

1. Put vehicle in NEUTRAL then raise and safely support the vehicle.
2. Remove the front wheel and the tire assemblies.

   WARNING
   Either remove or tape down the brake pads so they don’t fall out of the caliper guides.

   CAUTION
   Do not let the calipers hang by their hoses.

3. Install a wheel nut to secure each brake disc in place.
4. Remove the bolts and position both of the calipers to the side.
5. Remove the cotter pins and the nuts from both of the outer tie rods.

   NOTE: Use caution when installing the tie rod end remover tool (211-001) so you don’t damage the tie rod dust boots. Apply a small amount of grease to the tie rod stud.

6. Use the tie rod end remover tool (211-001), separate the tie rod ends from the knuckles.
7. Unclip the right and left wheel anti-lock sensor wiring harnesses from the locators on the chassis. These are located above the stabilizer bar brackets.

   CAUTION
   Do not let the wheel knuckle hang freely. It is possible to overextend and internally separate the inner CV joint. Separate both of the axle halfshafts from the front axle.

   CAUTION
   Make sure to protect the machined sealing surfaces on each axle.

8. Remove both of the pinch bolts and disconnect the upper ball joints.
9. Put the vehicle in NEUTRAL then raise and safely support the vehicle.
10. Remove the lower engine splash shield, if present.

    WARNING
    Tape up the U-joint bearing caps so they don’t fall off of the U-joint.

    CAUTION
    Put alignment marks on the front axle pinion flange in its relation to the front driveshaft.

11. Remove and throw away the bolts and straps. Secure the driveshaft to the side.

    NOTE: Use the axle service plug set (205-S358) to plug the axle openings.

12. Secure the axle housing to an appropriate lift.
13. Remove and throw away the bolts.
14. Lower the axle 1 inch (25 mm) and move it to the right 0.75 inch (19 mm), as you guide the left axle halfshaft out of the axle.
15. Disconnect the vent hose from the front axle housing.
16. Lower the axle from the vehicle.

To Install:

CAUTION
A new retainer circlip must be installed on the left inboard CV joint housing. If installing the original axle housing, install a new retainer circlip on the right side.

CAUTION
Be certain the halfshaft circlips fully seat.

1. Lift the axle into the vehicle.
2. Connect the vent hose to the front axle housing.
3. Guide the left axle halfshaft into the axle.
4. Install new bolts. Torque to 49 ft-lb (66 Nm).
5. Remove the axle housing from the lift.
6. Install new driveshaft bolts and straps.
7. If present, install the lower engine splash shield.
8. Safely lower the vehicle.
9. Connect the upper ball joints and install both of the pinch bolts. Torque to 35 ft-lb (48 Nm).
10. Clip the right and left wheel anti-lock sensor wiring harnesses to the locators on the chassis. These are located above the stabilizer bar brackets.
11. Rejoin the tie rod ends to the knuckles.
12. Install the cotter pins and the nuts to both of the outer tie rods. Torque to 67 ft-lb (91 Nm).
13. Put both calipers into their original positions and install the bolts. Torque to 24 ft-lb (33 Nm).
14. Remove the wheel nuts placed during removal to secure each brake disc in place.
15. Install the front wheel and the tire assemblies.
16. Fill the front axle with the correct type and amount of lubricant.
17. Safely lower the vehicle.