Installation Procedure
- NOTE:
- Ensure that the sealing surface is clear of oil, grease and old sealant material.
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- The bolts must be installed and fastened to final torque specification immediately after the component is installed.
Apply a 4.0 mm (0.158 in) bead of sealer (1) to the oil pan sealing surface. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Ensure the alignment pins are properly aligned when installing the oil pan.
Lower Oil Pan (1) - Install NEW
Oil Pan Bolt (1) - Install and hand tighten [23x]
- Oil Pan Bolt (1) - Tighten in sequence [23x] - Fastener Specifications
- NOTE:
The front axle may have to be maneuvered to install it into the vehicle.
Front Axle (1) - Install
- Front Axle Vent Hose - Connect
- CAUTION:
Refer to Fastener Caution .
Front Differential Carrier Bolt (1) - Install and tighten - Fastener Specifications
Front Differential Carrier Bolt (2) - Install
- Front Differential Carrier Bracket Nut (1) - Install and tighten - Fastener Specifications
Drivetrain and Front Suspension Frame Front Crossmember (1) - Install
Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Install [4x]
- Using the EN-45059-A Angle Meter, install and tighten the 4 drivetrain and front suspension frame reinforcement nuts (1). Fastener Specifications
- CAUTION:
Refer to Torque-to-Yield Fastener Caution
Front Differential Carrier Bolt (2) - Install NEW
- Front Differential Carrier Nut (1) - Install
- Using the EN-45059-A Angle Meter, tighten the front differential carrier nut (1). Fastener Specifications
Connect the front drive axle actuator electrical connector (1).
- Reposition the harness and secure the two harness retainers (2).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- 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.
- Front Axle Propeller Shaft (1) - Install
- Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
- Front Axle Propeller Shaft Washer (3) - Install [3x]
- Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
- NOTE:
Prior to installing the front shock absorber, you MUST apply anti-corrosion wax to the frame shock tower.
Apply anti-corrosion wax to the frame shock tower. ANTI-CORROSION TREATMENT AND REPAIR
- Front Shock Absorber (1) - Install
- {If Equipped} Connect the electrical connector at the shock absorber.
- NOTE:
Using a jack stand support the lower control arm to prevent over-articulation of the front lower control arm ball joint.
Front Shock Absorber Bolt (1) - Install and tighten [2x] - Fastener Specifications
Front Shock Absorber Nut (1) - Install and tighten [3x] - Fastener Specifications
Front Wheelhouse Liner (1) - Install
- NOTE:
Quantity of fasteners may vary based on option content.
Front Wheelhouse Liner Bolt (1) - Install and tighten [3x] - Fastener Specifications
- NOTE:
Quantity of fasteners may vary based on option content.
Front Wheelhouse Liner Bolt (1) - Install and tighten [3x] - Fastener Specifications
- NOTE:
Quantity of fasteners may vary based on option content.
Front Wheelhouse Liner Retainer (2) - Install
- Front Wheelhouse Liner Bolt (1) - Install and tighten [3x] - Fastener Specifications
- NOTE:
Quantity of fasteners may vary based on option content.
Front Wheelhouse Liner Bolt (1) - Install and tighten [3x] - Fastener Specifications
{If equipped} Front Tire Front Air Deflector Bolt (1) - Install and tighten - Fastener Specifications
Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.
Front Wheel Drive Shaft Seal (2) - Install NEW
- Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
- Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Some components not shown for graphic clarity.
Install the front wheel drive half shaft (1) into the wheel hub.
- Install the front wheel drive half shaft (1) into the front axle.
- Ensure that the left front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
- Support the steering knuckle with a suitable jack stand.
Front Upper Control Arm Ball Stud Nut (1) - Install and tighten - Fastener Specifications
Steering Linkage Outer Tie Rod Nut (1) - Install and tighten - Fastener Specifications
Install the front wheel speed sensor wiring harness bracket (2).
- Front Wheel Speed Sensor Bracket Bolt (1) - Install and tighten - Fastener Specifications
Front Wheel Speed Sensor (2) - Install
- Front Wheel Speed Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor Bracket (4) - Install
- Front Wheel Speed Sensor Bracket Bolt (3) - Install and tighten - Fastener Specifications
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- 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.
- Front Brake Caliper (1) - Install
- Front Brake Caliper Bolt (2) - Install and tighten [2x] - Fastener Specifications
Front Brake Hose Bracket Bolt (1) - Install and tighten - Fastener Specifications
- NOTE:
Only the left front wheel is equipped with the front disc brake pad wear sensor.
Front Disc Brake Pad Wear Sensor (1) @Front Brake Caliper - Install
Remove any buildup from the front differential carrier output shaft lead in chamfer (1) using an abrasive pad and wipe clean with a shop cloth.
Front Wheel Drive Shaft Seal (2) - Install NEW
- Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
- Apply a thin coating of grease to the splines of the front wheel drive half shaft and front differential carrier output shaft. Adhesives, Fluids, Lubricants, and Sealers
- NOTE:
Some components not shown for graphic clarity.
Install the front wheel drive half shaft (1) into the wheel hub.
- Install the front wheel drive half shaft (1) into the front axle.
- Ensure that the right front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.
- Support the steering knuckle with a suitable jack stand.
Front Upper Control Arm Ball Stud Nut (1) - Install and tighten - Fastener Specifications
Steering Linkage Outer Tie Rod Nut (1) - Install and tighten - Fastener Specifications
Install the front wheel speed sensor wiring harness bracket (2).
- Front Wheel Speed Sensor Bracket Bolt (1) - Install and tighten - Fastener Specifications
Front Wheel Speed Sensor (2) - Install
- Front Wheel Speed Sensor Bolt (1) - Install and tighten - Fastener Specifications
- Front Wheel Speed Sensor Bracket (4) - Install
- Front Wheel Speed Sensor Bracket Bolt (3) - Install and tighten - Fastener Specifications
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- 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.
- Front Brake Caliper (1) - Install
- Front Brake Caliper Bolt (2) - Install and tighten [2x] - Fastener Specifications
Front Brake Hose Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Have an assistant apply the brakes.
- CAUTION:
Refer to Torque-to-Yield Fastener Caution
Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications
- CAUTION:
Refer to Torque-to-Yield Fastener Caution
Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications
- Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation (Steel Wheel) , or Tire and Wheel Removal and Installation (Aluminum Wheel)
Front Differential Carrier Oil Filler Plug (1) - Remove
- Inspect the gear lubricant level, it should be 16 - 22 mm (0.6-0.9 in) below the plug opening.
- If the level is low, add gear lubricant until the level is 16 - 22 mm (0.6-0.9 in) below the plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers
- Front Differential Carrier Oil Filler Plug (1) - Install and tighten - Fastener Specifications
{with RC1} Install the underbody skid shield:
- Underbody Skid Shield (3) - Install
- Underbody Splash Shield Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Underbody Skid Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
{With WTX} Install the underbody skid shield:
- Underbody Skid Shield (2) - Install
- Underbody Skid Shield Bolt (1) - Install and tighten [4x] - Fastener Specifications
- NOTE:
Support the front stabilizer shaft.
Front Stabilizer Shaft (3) - Install
- Front Stabilizer Shaft Clamp (2) - Install [2x]
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- 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.
- Front Stabilizer Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
Front Stabilizer Shaft Link@Front Lower Control Arm - Install
- Front Stabilizer Shaft Link Nut (1) - Install and tighten - Fastener Specifications
Front Stabilizer Shaft Link@Lower Control Arm - Install
- Front Stabilizer Shaft Link Nut (1) - Install and tighten - Fastener Specifications
- Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
Refer to Fastener Caution .
Refer to Component Fastener Tightening Caution .