Halfshaft

REMOVAL & INSTALLATION

This procedure only applies to the 4WD models.

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the cotter pin and lock cap from the halfshaft.

   Fig. 2: Remove the cotter pin, discard it , then remove the lockcap

4. While applying the brakes, remove the locknut from the halfshaft.

   Fig. 3: Retain the rotor to remove the locknut from the halfshaft

   Fig. 4: Make sure that there are a few lug nuts on the rotor during the locknut removal

5. Remove the cotter pin and locknut to the tie rod end and disconnect the tie rod end from the knuckle.
6. Remove the lower ball joint bolts from the steering knuckle.

   Fig. 5: Remove the lower ball joint bolts . . .

   Fig. 6: . . . then pull the arm down slightly

7. 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.

   Fig. 7: Place matchmarks on the halfshaft and side gear assemblies

   Fig. 8: Loosen and remove the bolts on the halfshaft

8. 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.

   Fig. 9: Pull the control arm down to extract the halfshaft

   NOTE: 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.

   Fig. 10: Inspect the seal prior to halfshaft installation

   To install:

   NOTE: Coat the halfshaft splines with anti-seize compound to prevent spline seizure. This will help for future halfshaft removal.

9. Insert the halfshaft into position.

   Fig. 11: Insert the driveshaft through the hub first

10. Connect the halfshaft to the steering knuckle.
11. Connect the inner halfshaft joint to the side gear and tighten the six bolts to 51 ft. lbs. (61 Nm).
12. Connect the lower ball joint, then tighten the bolts to 94 ft. lbs. (127 Nm).
13. Install the tie rod end, tighten the nut to 36 ft. lbs. (49 Nm) and insert a new cotter pin.
14. Install the halfshaft nut.
15. While a helper is applying the brakes, tighten the drive shaft locknut to:
    • 1991 — 137 ft lbs. (186 Nm)
    • 1992–93 models — 166 ft. lbs. (226 Nm)
    • 1994–97 models — 152 ft. lbs. (206 Nm)
    1. Install the lock cap and new cotter pin.
16. On models with a ABS speed sensor, secure the sensor to 69 inch lbs. (8 Nm).
17. Install the front wheel, hand tighten the lugnuts and lower the vehicle.
18. tighten the lugnuts to specifications.
19. Check the front end alignment.