Installation Procedure
If the transfer case front output shaft boot (1) was removed, perform the following:
- Loosely install a NEW transfer case front output shaft boot clamp (2) to the groove of the transfer case front output shaft boot (1).
- Install the transfer case front output shaft boot (1) to the front axle propeller shaft groove ensuring that it is completely engaged.
- Using the DT-35910 Drive Axle Seal Clamp Pliers (3), crimp the transfer case front output shaft boot clamp (2) until the final crimped diameter (a) of 37.5 mm (1.48 in) is achieved.
Loosely install a NEW transfer case front output shaft boot clamp (3) into the groove of the transfer case front output shaft boot (2).
- Front Axle Propeller Shaft (1) - Install
Prepare the 6 front axle propeller shaft bolts (1) for installation as follows:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Align the marks made between the front axle propeller shaft (2) and the front differential carrier flange.
- Front Axle Propeller Shaft Washer (3) - Install [3x]
- Install and tighten the 6 front axle propeller shaft bolts (1) in a crisscross pattern. Fastener Specifications
Ensure that the front transfer case front output shaft boot (2) is completely engaged into the transfer case front output shaft.
- Ensure that the front transfer case front output shaft boot clamp (1) is completely engaged into the front transfer case front output shaft boot (2).
Using the DT-35910 Drive Axle Seal Clamp Pliers (1), crimp the transfer case front output shaft boot clamp (2) until the final crimped diameter (a) of 37.5 mm (1.48 in) is achieved.
Transmission Mount (2) - Install
- Transmission Mount Bolt (1) - Loosely install
Transmission Mount Bracket Bolt (1) - Loosely install [4x]
- Remove the jack from beneath the transmission.
Front Axle Propeller Shaft Heat Shield (3) - Install
- Front Axle Propeller Shaft Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Front Axle Propeller Shaft Heat Shield Stud (2) - Install and tighten - Fastener Specifications
Exhaust Pipe Clamp (1) - Install NEW
Catalytic Converter Gasket (2) - Install NEW
- Warm Up Three-Way Catalytic Converter (1) - Install
Catalytic Converter Brace Bolt (1) - Install and tighten - Fastener Specifications
Catalytic Converter Brace Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Use hand tools only when tightening the exhaust pipe clamp.
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Catalytic Converter Gasket (2) - Install NEW
- Exhaust Muffler (1) - Install
{ If equipped } Front Crossmember Brace (2) - Install
- { If equipped } Front Crossmember Brace Nut (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install
Catalytic Converter Nut (1) - Install and tighten [2x] - Fastener Specifications
Floor Panel Reinforcement (2) - Install
- Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Install and tighten [6x] - Fastener Specifications
- NOTE:
A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers
CAUTION:Refer to Component Fastener Tightening Caution .
Using the EN-6179 Heated Oxygen Sensor Remover/Installer, install the heated oxygen sensor (1). Fastener Specifications
- Connect the electrical connector.
Catalytic Converter Heat Shield (1) - Install
Catalytic Converter Heat Shield Nut (2) - Install and tighten - Fastener Specifications
- Catalytic Converter Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Bolt (1) - Install [3x] - Fastener Specifications
- NOTE:
A special anti-seize compound is used on the heated oxygen sensor threads. The compound consists of liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound already applied to the threads. IF a sensor is removed and is to be reinstalled, the threads MUST have an anti-seize compound applied before installation. Adhesives, Fluids, Lubricants, and Sealers
Using the EN-6179 Heated Oxygen Sensor Remover/Installer, install the heated oxygen sensor (1). Fastener Specifications
- Connect the electrical connector.
- Inspect the exhaust system for leaks.
- Remove the support and lower the vehicle.
Refer to Fastener Caution .
For proper bolt alignment, loosely install all mount bolts prior to tightening to specifications.