Removal Procedure
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
- Lower the drivetrain and front suspension frame assembly. Drivetrain and Front Suspension Cradle Removal and Installation (AWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (RWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (Blackwing)
- Drain the Front Differential Carrierfluid. Front Axle Lubricant Replacement
Air Cleaner Outlet Duct Clamp (1) - Loosen [2x]
- Evaporative Emission Canister Purge Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Disconnect the electrical connector.
Air Cleaner Outlet Duct (1) - Remove
- Disconnect the electrical connector and remove all wiring harnesses from the air cleaner assembly.
Air Cleaner Bolt (1) - Remove
Air Cleaner Assembly (1) - Remove
- Disconnect and reposition electrical connectors as necessary.
- CAUTION:
Refer to Heated Oxygen and Oxygen Sensor Caution .
CAUTION:The use of excessive force may damage the threads in the exhaust manifold/pipe.
NOTE:The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
NOTE:The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield (1) - Remove
Retainer (1) - Unclip
Water Pump Cover Bolt (1) - Remove [3x]
- Water Pump Cover (2) - Remove
Engine Mount Nut (1) - Remove
- Use the EN-51007 Global Engine Support Fixture to raise the engine off the engine mount.
Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]
Engine Mount Bracket (1) - Remove
- Ensure the phenolic spacer remains in place.
Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Remove [6x]
- Floor Panel Reinforcement (2) - Remove
Catalytic Converter Nut (1) - Remove [2x]
Electrical Connector (1) @ Exhaust Control Valve Actuator - Disconnect [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Separate
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Separate
Exhaust Muffler (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
Exhaust Pipe Clamp (1) - Loosen
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Catalytic Converter Brace Bolt (2) - Remove [2x]
- Catalytic Converter Brace (3) - Remove
Warm Up Three-Way Catalytic Converter (1) - Remove
- Exhaust Pipe Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
Front Axle Propeller Shaft Heat Shield Bolt (1) - Remove
- Front Axle Propeller Shaft Heat Shield Stud (2) - Remove
- Front Axle Propeller Shaft Heat Shield (3) - Remove
- Support the transmission with an appropriate jack.
Transmission Mount Bracket Bolt (1) - Remove [4x]
- NOTE:
The transmission mount bolt is retained in the mount, loosen the bolt to disengage the threads and remove the mount and bolt as an assembly.
Transmission Mount Bolt (1) - Remove
- Transmission Mount (2) - Remove
Transfer Case Front Output Shaft Boot Clamp (1) @ Transfer Case Front Output Shaft - Remove and DISCARD
- Release the transfer case front output shaft boot (2) from the groove in the transfer case front output shaft.
Mark the relationship between the front axle propeller shaft (2) and the front differential carrier flange with a grease pencil.
- Front Axle Propeller Shaft Bolt (1) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
Front Axle Propeller Shaft (1) - Remove
Inspect the transfer case front output shaft boot (1), if damage is found, remove and DISCARD the transfer case front output shaft boot clamp (2) and the transfer case front output shaft boot (1).
Have an assistant apply the brakes.
CAUTION:DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut (1) - Remove and DISCARD
Install the DT-45859 Axle Remover (1) to the front wheel hub and secure with 3 wheel nuts (2) hand tightened.
- Using the DT-45859 Axle Remover (1), release the front wheel drive half shaft from the front wheel hub.
- Remove the 3 wheel nuts (2) and the DT-45859 Axle Remover (1) from the front wheel hub.
Install the DT-45341 Rear Wheel Drive Shaft Removal Tool (1), GE-47829 Slide Hammer Extension (3) and GE-02619-A Slide Hammer (4) to the front wheel drive half shaft (2).
- Release the front wheel drive half shaft (2) from the front wheel drive intermediate shaft.
- Remove the GE-02619-A Slide Hammer (4), GE-47829 Slide Hammer Extension (3) and DT-45341 Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
Front Wheel Drive Half Shaft (1) - Remove
Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Remove and DISCARD
- Front Wheel Drive Intermediate Shaft Seal (2) - Remove and DISCARD
Front Wheel Drive Intermediate Shaft Bracket Bolt (2) - Remove [3x]
- Front Wheel Drive Intermediate Shaft Bracket (1) - Remove
- Thoroughly clean and inspect the front wheel drive intermediate shaft bracket for damage.
- If damaged, replace the front wheel drive intermediate shaft bracket.
Attach the DT - 44467 Output Shaft Assembly Remover/Installer (1) to the shaft.
- Attach the GE-6125-1B Slide Hammer (2) to the DT-44467 Output Shaft Assembly Remover/Installer (1).
- Use the tools to remove the Front Wheel Drive Intermediate Shaft (3) from the front differential carrier.
- Front Wheel Drive Intermediate Shaft (3) - Remove
- Front Wheel Drive Intermediate Shaft Retaining Ring (4) - Remove and DISCARD
Have an assistant apply the brakes.
CAUTION:DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut (1) - Remove and DISCARD
Install the DT-45859 Axle Remover (1) to the front wheel hub and secure with 3 wheel nuts (2) hand tightened.
- Using the DT-45859 Axle Remover (1), release the front wheel drive half shaft from the front wheel hub.
- Remove the 3 wheel nuts (2) and the DT-45859 Axle Remover (1) from the front wheel hub.
Install the DT-45341 Rear Wheel Drive Shaft Removal Tool (1), GE-47829 Slide Hammer Extension (3) and GE-02619-A Slide Hammer (4) to the front wheel drive half shaft (2).
- Release the front wheel drive half shaft (2) from the front differential carrier.
- Remove the GE-02619-A Slide Hammer (4), GE-47829 Slide Hammer Extension (3) and DT-45341 Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
Partially remove the front wheel drive half shaft (1) from the front differential carrier.
- Install the DT-51504 Seal Protector (2) into the front axle shaft seal.
Front Wheel Drive Half Shaft (1) - Remove
Front Wheel Drive Shaft Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Remove and DISCARD
Front Axle Vent Hose (1) - Remove
- Using the engine support fixture, carefully lower the engine assembly enough to allow the front differential carrier assembly to be removed through the right wheel opening.
Position a transmission jack beneath the Front Differential Carrier.
- Firmly secure the Front Differential Carrier to the transmission jack.
- Front Differential Carrier Bolt (1) - Remove [2x]
- Front Differential Carrier Bolt (2) - Remove
Front Differential Carrier Bolt (1) - Remove
Front Differential Carrier (1) - Remove
Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.
Insert suitable flat edge tool into gaps between bracket and mounting surface and apply alternate and even pressure to gently rock bracket out of mating recess.
The front wheel drive intermediate shaft bracket bearing is not serviced separately. If the bearing is worn or damaged, replace the front wheel drive intermediate shaft bracket assembly.
DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal