Important: Observe and accurately reference mark the positions of all driveline components relative to the propeller shaft prior to disassembly. These components include the propeller shafts, drive axles, pinion flange, inner axle shafts, etc. Reassemble all components in the exact relationship the components had to one another prior to disassembly. Follow the specifications, torque values and any measurement made prior to disassembly in order to maintain the factory system balance of the driveline components. System balance provides a smoother running driveline operation.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Position a drain pan under the inner axle shaft housing.
3. Remove the right side wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.



4. Remove the five axle shaft housing to carrier bolts.
5. Remove the shift cable housing assembly from the carrier.
6. Remove the two axle shaft housing to frame bracket bolts, nuts and washers.

Important: Do not allow the following components to fall out of the carrier assembly or become damaged:

•	The thrust washers

•	The clutch gear, which may remain attached to the inner axle shaft.

•	The clutch sleeve

•	The clutch shaft

7. Remove the inner axle shaft and housing assembly from the carrier.
8. Remove the inner axle shaft from the housing.

8.1.	Hold the housing in a vise by the carrier mounting flange.

8.2.	Tap out the shaft using a soft mallet.

8.3.	Separate the inner axle shaft and the clutch gear, if necessary.

9. Inspect the following components for wear:

•	The inner axle shaft pilot and the clutch shaft pilot bearing

•	The inner axle shaft seal and bearing

•	The shift cable housing seal

10. Replace as necessary. Refer to the correct procedure:

•	Clutch Shaft Bearing Replacement

•	Inner Shaft Seal and Bearing Replacement

•	Shift Cable Housing Seal Replacement

11. Clean the sealing surfaces of the inner axle shaft housing and the carrier with a chlorinated solvent.

Tools Required

J 33798 Hub Engagement Tool

1. Apply a bead of sealer to the carrier sealing surface.
2. Install the inner axle shaft into the housing.
3. Ensure that the following components are in place in the carrier assembly:

•	The thrust washers

•	The clutch shaft

•	The clutch sleeve

•	The clutch gear




4. Install the clutch gear thrust washer to the housing as shown. Use grease in order to hold the washer in place.
5. Install the axle shaft and housing assembly to the carrier.
6. Install the axle shaft housing to carrier bolt at the 1 o'clock position. Tighten the bolt finger tight.
7. Position the shift cable housing on the axle housing to carrier flange.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Pull the axle shaft and housing assembly down in order to install the remaining bolts.

Tighten
Tighten the five bolts to 48 N·m (36 lb ft).

9. Install the two axle shaft housing to frame bracket bolts, nuts and washers.

Tighten
Tighten the nuts to 98 N·m (72 lb ft).




10. Inspect the operation of the shift mechanism. Use J 33798 . Insert the tool into the shift fork. Inspect for rotation of the axle shaft.
11. Install the shift cable and indicator assembly to the shift cable housing.
12. Install the right side wheel drive axle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
13. Inspect the axle lubricant level and add as needed. Use the proper fluid. Refer to Lubrication Specifications .
14. Lower the vehicle.