Front Wheel Drive Intermediate Shaft Seal Replacement

Single Use Fasteners and Components Front Wheel Drive Intermediate Shaft Seal Front Wheel Drive Shaft Nut Front Wheel Drive Shaft Retaining Ring Front Wheel Drive Shaft Seal Special Tools Front Suspension CH-42188-B Ball Joint Separator CH-43631 Ball Joint Separator Equivalent regional tools: Special Tools Wheel Drive Shafts DT-45859 Axle Remover Equivalent regional tools: Special Tools

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

Brake Dust Warning Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 1

3. {without RC1} Remove the underbody skid shield: 3.1. Underbody Skid Shield Bolt (1) » Remove [4x] 3.2. Underbody Skid Shield (2) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 2

4. {with RC1} Remove the underbody skid shield: 4.1. Underbody Skid Shield Bolt (1) » Remove [2x] 4.2. Underbody Splash Shield Bolt (2) » Remove [2x] 4.3. Underbody Skid Shield (3) » Remove
5. Remove the right front tire and wheel assembly. Tire and Wheel Removal and Installation
6. Have an assistant apply the brakes.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 3

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.

7. Front Wheel Drive Shaft Nut (1) » Remove and DISCARD

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 4

8. Install the DT-45859 Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
9. Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
10. Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 5

11. Front Brake Hose Bracket Bolt (1) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 6

12. Front Brake Caliper Bolt (2) » Remove [2x]

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

13. Remove the brake caliper and support with heavy mechanics wire. (1)

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 7

14. Front Wheel Speed Sensor Bolt (1) » Remove
15. Front Wheel Speed Sensor (2) » Remove
16. Front Wheel Speed Sensor Bracket Bolt (3) » Remove
17. Front Wheel Speed Sensor Bracket (4) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 8

18. {Without F47} Front Wheel Speed Sensor Bracket Bolt (1) » Remove 18.1. Remove the front wheel speed sensor wiring harness bracket (2).

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 9

19. {With F47} Electronic Suspension Rear Vertical Accelerometer Bolt (2) » Remove 19.1. Remove the harness (1) and the electronic suspension wheel front vertical accelerometer (3).

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 10

20. Steering Linkage Outer Tie Rod Nut (1) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 11

Caution

Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.

21. Using CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.

Note

Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.

22. Support the lower control arm with a suitable jack stand.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 12

23. Front Stabilizer Shaft Link Nut (1) » Remove
24. Front Stabilizer Shaft Link @ Lower Control Arm » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 13

25. Front Upper Control Arm Ball Stud Nut (1) » Loosen

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 14

26. Using the CH-42188-B Ball Joint Separator (1), separate the right front upper control arm (2) from the steering knuckle.
27. Remove the CH-42188-B Ball Joint Separator (1) from the right front upper control arm (2) and the steering knuckle.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 15

28. Front Upper Control Arm Ball Stud Nut (1) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 16

Caution

Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

Note

Some components not shown for graphic clarity.

29. Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 17

Note

Some components not shown for graphic clarity.

30. Remove the front wheel drive half shaft (1) from the front axle.
31. Remove the front wheel drive half shaft (1) from the wheel hub.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 18

32. Front Wheel Drive Shaft Retaining Ring (1) » Remove and DISCARD
33. Front Wheel Drive Shaft Seal (2) » Remove and DISCARD

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 19

34. Disconnect the front drive axle actuator electrical connector (1) and reposition.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 20

35. Front Drive Axle Actuator Bolt (1) » Remove [4x]
36. Front Drive Axle Actuator (2) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 21

Note

Some components not shown for graphic clarity.

37. { With L84, L87 } Electrical Connector @ Heater Coolant Pump (2) » Disconnect 37.1. Heater Water Auxiliary Pump Bolt (1) » Remove 37.2. Remove the heater coolant pump and heater water auxiliary pump bracket (2) as assembly and position aside.

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 22

38. Front Differential Carrier Bracket Nut (1) » Remove
39. Front Differential Carrier Bolt (2) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 23

40. Front Drive Axle Inner Shaft Housing Bolt (1) » Remove [4x]

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 24

41. Front Drive Axle Inner Shaft Housing (1) » Remove

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 25

42. Front Wheel Drive Intermediate Shaft Seal (1) » Remove and DISCARD Installation Procedure

43. Front Wheel Drive Intermediate Shaft Seal (1) » Install NEW

44. Front Drive Axle Inner Shaft Housing (1) » Install

45. 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: 3.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 3.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 3.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 3.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution

Refer to Fastener Caution.

4. Front Drive Axle Inner Shaft Housing Bolt (1) » Install and tighten [4x] — Fastener Specifications

5. Front Differential Carrier Bolt (2) » Install

6. Front Differential Carrier Bracket Nut (1) » Install and tighten — Fastener Specifications

Note

Some components not shown for graphic clarity.

7. { With L84, L87 } Install the heater coolant pump and heater water auxiliary pump bracket (2) as assembly. 7.1. Heater Water Auxiliary Pump Bolt (1) » Install and tighten — Fastener Specifications 7.2. Electrical Connector @ Heater Coolant Pump (2) » Connect

8. 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: 8.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 8.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 8.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 8.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

9. Front Drive Axle Actuator (2) » Install

10. Front Drive Axle Actuator Bolt (1) » Install and tighten [4x] — Fastener Specifications

11. Connect the front drive axle actuator electrical connector (1).

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 26

12. Front Differential Carrier Oil Filler Plug (1) » Remove
13. Inspect the gear lubricant level, it should be 16–22 mm (0.6-0.9 in) below the plug opening.
14. 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

Caution

Refer to Component Fastener Tightening Caution.

15. Front Differential Carrier Oil Filler Plug (1) » Install and tighten — Fastener Specifications

Front Wheel Drive Intermediate Shaft Seal Replacement — figure 27

16. 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.

17. Front Wheel Drive Shaft Seal (2) » Install NEW

18. Front Wheel Drive Shaft Retaining Ring (1) » Install NEW

19. 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.

20. Install the front wheel drive half shaft (1) into the wheel hub.

21. Install the front wheel drive half shaft (1) into the front axle.

22. Ensure that the right front wheel drive half shaft (1) is fully seated in front differential carrier by pulling on the inner joint.

23. Support the steering knuckle with a suitable jack stand.

24. Front Upper Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

25. Front Stabilizer Shaft Link @ Lower Control Arm » Install

26. Front Stabilizer Shaft Link Nut (1) » Install and tighten — Fastener Specifications

27. Steering Linkage Outer Tie Rod Nut (1) » Install and tighten — Fastener Specifications

28. {Without F47} Install the front wheel speed sensor wiring harness bracket (2). 28.1. Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

29. {With F47} Install the harness (1) and the electronic suspension wheel front vertical accelerometer (3). 29.1. Electronic Suspension Rear Vertical Accelerometer Bolt (2) » Install and tighten — Fastener Specifications

30. Front Wheel Speed Sensor (2) » Install

31. Front Wheel Speed Sensor Bolt (1) » Install and tighten — Fastener Specifications

32. Front Wheel Speed Sensor Bracket (4) » Install

33. Front Wheel Speed Sensor Bracket Bolt (3) » Install and tighten — Fastener Specifications

34. 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: 34.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 34.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 34.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 34.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

35. Front Brake Caliper (1) » Install

36. Front Brake Caliper Bolt (2) » Install and tighten [2x] — Fastener Specifications

37. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

38. Have an assistant apply the brakes.

Caution

Refer to Torque-to-Yield Fastener Caution

39. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications

40. Install the right front tire and wheel assembly. Tire and Wheel Removal and Installation

41. {with RC1} Install the underbody skid shield: 41.1. Underbody Skid Shield (3) » Install 41.2. Underbody Splash Shield Bolt (2) » Install and tighten [2x] — Fastener Specifications 41.3. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

42. {Without RC1} Install the underbody skid shield: 42.1. Underbody Skid Shield (2) » Install 42.2. Underbody Skid Shield Bolt (1) » Install and tighten [4x] — Fastener Specifications

43. Remove the support and lower the vehicle.

44. Connect the battery negative cable.