Installation Procedure
Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Install NEW
- Apply a small amount of lubricant to the Front Wheel Drive Intermediate Shaft (2)splines. Adhesives, Fluids, Lubricants, and Sealers
- Install the Front Wheel Drive Intermediate Shaft (2)into the Front Differential Carrier (3).
- NOTE:
The Front Wheel Drive Intermediate Shaft and Front Differential Carrier are to be installed as a assembly.
Position and secure the Front Differential Carrier (2)on a transmission jack.
- Front Wheel Drive Intermediate Shaft (1)and the Front Differential Carrier (2) - Install
- CAUTION:
Refer to Fastener Caution .
Front Differential CarrierBolt (1) - Install and hand tighten
Front Differential CarrierBolt (1) - Install and hand tighten [ 2x ]
- Front Differential CarrierBolt (2) - Install and hand tighten
- Front Differential CarrierBolt - Tighten [ 4x ] - Fastener Specifications
- Remove the transmission jack from the Front Differential Carrier.
- Using the engine support fixture, carefully raise the engine assembly to it's original position.
Front Axle Vent Hose (1)Install
Front Wheel Drive Intermediate Shaft Bracket (1) - Install
- Front Wheel Drive Intermediate Shaft Housing Bolt (2) - Install and tighten [ 3x ] - Fastener Specifications
Apply a small amount of lubricant to the front wheel drive intermediate shaft splines. Adhesives, Fluids, Lubricants, and Sealers
- Front Wheel Drive Intermediate Shaft Seal (2) - Install NEW
- Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Install NEW
Apply a small amount of grease to the front wheel drive intermediate shaft splines. Adhesives, Fluids, Lubricants, and Sealers
NOTE:Ensure that the front wheel drive half shaft (1) is securely engaged to the front wheel drive intermediate shaft.
Front Wheel Drive Half Shaft (1) - Install
Have an assistant apply the brakes.
Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications
Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Install NEW
Front Wheel Drive Half Shaft (1) - Install
Partially install the Front Wheel Drive Half Shaft (1) into the Front Differential Carrier.
- Remove the DT-51504 Seal Protector (2)from the front axle shaft seal.
- Completely install the Front Wheel Drive Half Shaft (1) into the Front Differential Carrier.
Have an assistant apply the brakes.
Front Wheel Drive Shaft Nut (1) - Install NEW and tighten - Fastener Specifications
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 ]
- CAUTION:
Refer to Fastener Caution .
NOTE:Ensure that the snubber is properly aligned with the tabs on the transmission mount prior to tightening.
Transmission Mount Bolt (1) - Tighten - Fastener Specifications
Transmission Mount Bracket Bolt (1) - Tighten [ 4x ] - Fastener Specifications
- 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 - Fastener Specifications
- Front Axle Propeller Shaft Heat Shield Stud (2) - Install and tighten - Fastener Specifications
Catalytic Converter Gasket (3) - Install NEW
- Exhaust Pipe Clamp (2) - Install NEW
- Warm Up Three-Way Catalytic Converter (1) - Install
Catalytic Converter Brace (3) - Install
- Catalytic Converter Brace Bolt (2) - Install and tighten [ 2x ] -
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [ 2x ] -
- NOTE:
Inspect on all sides of the warm up three-way catalytic converter to verify it is fully seated prior to tightening the exhaust pipe clamp.
Exhaust Pipe Clamp (1) - Tighten -
Catalytic Converter Gasket (2) - Install NEW
- Exhaust Muffler (1) - Install
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
Electrical Connector (1) @ Exhaust Control Valve Actuator - Connect [ 2x ]
Catalytic Converter Nut (1) - Install [ 2x ] -
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.
- Ensure the phenolic spacer remains in place.
Engine Mount Bracket (1) - Install
- CAUTION:
Refer to Fastener Caution .
CAUTION:Refer to Torque-to-Yield Fastener Caution .
Engine Mount Bracket Bolt (1) - Install NEW and tighten [ 4x ] - Fastener Specifications
- Use the EN-51007 Global Engine Support Fixture to lower the engine onto the engine mount.
Engine Mount Nut (1) - Install NEW and tighten - Fastener Specifications
Water Pump Cover (2) - Install
- Water Pump Cover Bolt (1) - Install and tighten [ 3x ] - Fastener Specifications
Retainer (1) - Install
Turbocharger Heat Shield (1) - Install
Turbocharger Heat Shield Bolt (1) - Install and tighten [ 2x ] -
Turbocharger Heat Shield Bolt (1) - Install and tighten [ 2x ] -
- 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.
Air Cleaner Assembly (1) - Install
Air Cleaner Bolt (1) - Install and tighten - Fastener Specifications
- Connect the electrical connector and install all wiring harnesses to the air cleaner assembly.
Air Cleaner Outlet Duct (1) - Install
- Connect the electrical connector.
Positive Crankcase Ventilation Tube (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (1) - Tighten [ 2x ] Fastener Specifications
- Inspect the exhaust system for leaks.
- Install the drivetrain and front suspension frame assembly. Drivetrain and Front Suspension Cradle Removal and Installation (AWD)Drivetrain and Front Suspension Cradle Removal and Installation (RWD)
- Install the front differential carrier oil drain plug. Front Axle Lubricant Replacement
- Lower the vehicle.
Ensure that the front wheel drive half shaft (1) is securely engaged to the front differential carrier.
For proper bolt alignment, loosely install all mount bolts prior to tightening to specifications.
Ensure that the catalytic converter gasket is fully seated on the warm up three-way catalytic converter inlet flange.
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.