Transmission Fluid Cooler Inlet and Outlet Pipe Replacement

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (L84, L87, 4WD with WTX, without F47) Single Use Fasteners and Components Transmission Cooling Transmission Fluid Cooler Pipe Fitting Seal [2x] Transmission Fluid Cooler Seal Engine Heating and Cooling Air Conditioning Compressor and Condenser Hose Seal [2x] Front Drive Axle Front Differential Carrier Bolt Front Wheel Drive Shaft Nut [2x] Front Wheel Drive Shaft Retaining Ring [2x] Front Wheel Drive Shaft Seal [2x] Special Tools Front Drive Axle EN-45059-A Angle Meter Equivalent regional tools: 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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 1

1. Remove the condenser, fan, and radiator assembly (1). Condenser, Fan, and Radiator Assembly Removal and Installation
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 2

3. Front Bumper Fascia Air Deflector Bolt (1) » Remove [10x]
4. Front Bumper Fascia Extension Bolt (2) » Remove [8x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 3

5. Pull the front bumper fascia extension (1) rearward and down from the front bumper fascia.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 4

6. Front Bumper Fascia Extension Bolt (2) » Remove [4x]
7. Front Bumper Fascia Extension Bolt @ Skid Shield (3) » Remove [2x]
8. Pull the front bumper fascia extension (4) rearward and down.
9. If equipped, release the wire harness retainer.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 5

10. Underbody Skid Shield Bolt (1) » Remove [2x]
11. Underbody Skid Shield (2) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 6

Note

Support the front stabilizer shaft.

12. Front Stabilizer Shaft Bolt (1) » Remove [4x]
13. Front Stabilizer Shaft Clamp (2) » Remove [2x]
14. Front Stabilizer Shaft Insulator (3) » Remove [2x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 7

15. Front Stabilizer Shaft Link Nut - Upper (1) @ Front Stabilizer Shaft » Remove [2x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 8

16. Front Stabilizer Shaft (1) » Remove
17. Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation
18. Have an assistant apply the brakes.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 9

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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 10

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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 11

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 12

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 13

25. 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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 14

27. Front Wheel Speed Sensor Bolt (1) » Remove
28. Front Wheel Speed Sensor (2) » Remove
29. Front Wheel Speed Sensor Bracket Bolt (3) » Remove
30. Front Wheel Speed Sensor Bracket (4) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 15

31. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
32. Remove the front wheel speed sensor wiring harness bracket (2).

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 16

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 17

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.

34. Using the 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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 18

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 19

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 20

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 21

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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 22

Note

Some components not shown for graphic clarity.

41. Remove the front wheel drive half shaft (1) from the front axle.
42. Remove the front wheel drive half shaft (1) from the wheel hub.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 23

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 24

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 25

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 26

Note

Only the left front wheel is equipped with the front disc brake pad wear sensor.

49. Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 27

50. 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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 28

52. Front Wheel Speed Sensor Bolt (1) » Remove
53. Front Wheel Speed Sensor (2) » Remove
54. Front Wheel Speed Sensor Bracket Bolt (3) » Remove
55. Front Wheel Speed Sensor Bracket (4) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 29

56. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
57. Remove the front wheel speed sensor wiring harness bracket (2).

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 30

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 31

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.

59. Using the 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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 32

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 33

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 34

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 35

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.

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

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 36

Note

Some components not shown for graphic clarity.

66. Remove the front wheel drive half shaft (1) from the front axle.

67. Remove the front wheel drive half shaft (1) from the wheel hub.

68. Front Wheel Drive Shaft Retaining Ring (1) » Remove and DISCARD

69. Front Wheel Drive Shaft Seal (2) » Remove and DISCARD

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 37

70. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 38

71. Unclip and reposition the chassis wiring harness bracket (1) away from the frame shock tower.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 39

72. Front Shock Absorber Nut (1) » Remove [3x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 40

73. Front Shock Absorber Bolt (1) » Remove [2x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 41

74. {If Equipped} Disconnect the electrical connector at the shock absorber.
75. Front Shock Absorber (1) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 42

76. Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
77. Front Axle Propeller Shaft Bolt (2) » Remove [6x]
78. Front Axle Propeller Shaft Washer (3) » Remove [3x]
79. Front Axle Propeller Shaft (1) » Reposition away

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 43

80. Disconnect the front drive axle actuator electrical connector (1).
81. Release the two harness retainers (2) and reposition harness.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 44

Note

Some components not shown for graphic clarity.

82. Electrical Connector @ Heater Coolant Pump (2) » Disconnect
83. Heater Water Auxiliary Pump Bolt (1) » Remove
84. Remove the heater coolant pump and heater water auxiliary pump bracket (2) as assembly and position aside.

Note

Ensure that the front axle is securely attached to the hydraulic jack.

85. Support the front axle with a hydraulic jack.

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 45

86. Front Differential Carrier Nut (1) » Remove
87. Front Differential Carrier Bolt (2) » Remove and DISCARD

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 46

88. Drivetrain and Front Suspension Frame Reinforcement Nut (1) » Remove [4x]
89. Drivetrain and Front Suspension Frame Reinforcement Bolt (2) » Remove [4x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 47

90. Drivetrain and Front Suspension Frame Front Crossmember (1) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 48

91. Front Differential Carrier Bracket Nut (1) » Remove
92. Front Differential Carrier Bolt (2) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 49

93. Front Differential Carrier Bolt (1) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 50

94. Front Axle Vent Hose » Disconnect

Note

The front axle may have to be maneuvered to remove it from the vehicle.

95. Front Axle (1) » Remove

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 51

96. Remove the transmission fluid auxiliary cooler pipe bracket nut (1).

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 52

Note

Some components not shown for graphic clarity.

97. Transmission Fluid Cooler Pipe Clip (1) » Open [2x]

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 53

Note

Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.

98. Remove the transmission fluid cooler pipe connector bolt (3).
99. Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission » Remove
100. Transmission Fluid Cooler Seal (1) » Remove and DISCARD

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 54

101. Maneuver the transmission cooler inlet and outlet pipe (1) as necessary to remove from under the vehicle. Installation Procedure

102. Maneuver the transmission cooler inlet and outlet pipe (1) as necessary to install.

103. Transmission Fluid Cooler Seal (1) » Install NEW

104. Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission » Install

Caution

Refer to Fastener Caution.

4. Install and tighten the transmission fluid cooler pipe connector bolt (3). Fastener Specifications

Note

Some components not shown for graphic clarity.

5. Transmission Fluid Cooler Pipe Clip (1) » Close [2x]

6. Install and tighten the transmission fluid auxiliary cooler pipe bracket nut (1). Fastener Specifications

Note

The front axle may have to be maneuvered to install it into the vehicle.

7. Front Axle (1) » Install

8. Front Axle Vent Hose » Connect

9. Front Differential Carrier Bolt (1) » Install and tighten — Fastener Specifications

10. Front Differential Carrier Bolt (2) » Install

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

12. Drivetrain and Front Suspension Frame Front Crossmember (1) » Install

13. Drivetrain and Front Suspension Frame Reinforcement Bolt (2) » Install [4x]

14. 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

15. Front Differential Carrier Bolt (2) » Install NEW
16. Front Differential Carrier Nut (1) » Install
17. Using the EN-45059-A Angle Meter, tighten the front differential carrier nut (1). Fastener Specifications

Note

Some components not shown for graphic clarity.

18. Install the heater coolant pump and heater water auxiliary pump bracket (2) as assembly.

19. Heater Water Auxiliary Pump Bolt (1) » Install and tighten — Fastener Specifications

20. Electrical Connector @ Heater Coolant Pump (2) » Connect

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

22. Reposition the harness and secure the two harness retainers (2).

23. Clean the residue from the threaded holes of the front differential drive pinion gear yoke with denatured alcohol and allow to dry.

24. 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: 24.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 24.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 24.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 24.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

25. Front Axle Propeller Shaft (1) » Reposition

26. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.

27. Front Axle Propeller Shaft Washer (3) » Install [3x]

28. 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.

29. Apply anti-corrosion wax to the frame shock tower. Anti-Corrosion Treatment and Repair
30. Front Shock Absorber (1) » Install
31. {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.

32. Front Shock Absorber Bolt (1) » Install and tighten [2x] — Fastener Specifications

33. Front Shock Absorber Nut (1) » Install and tighten [3x] — Fastener Specifications

34. Front Wheelhouse Liner - Left Side » Install — Front Wheelhouse Liner Replacement

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 55

35. 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.

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

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

38. 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.

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

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

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

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

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

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

45. Install the front wheel speed sensor wiring harness bracket (2).

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

47. Front Wheel Speed Sensor (2) » Install

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

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

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

51. 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: 51.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 51.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 51.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 51.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

52. Front Brake Caliper (1) » Install

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

54. 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.

55. Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Install

56. 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.

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

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

59. 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.

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

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

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

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

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

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

66. Install the front wheel speed sensor wiring harness bracket (2).

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

68. Front Wheel Speed Sensor (2) » Install

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

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

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

72. 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: 72.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 72.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 72.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 72.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

73. Front Brake Caliper (1) » Install

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

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

76. Have an assistant apply the brakes.

Caution

Refer to Torque-to-Yield Fastener Caution

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

Caution

Refer to Torque-to-Yield Fastener Caution

78. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications
79. Install the front tire and wheel assemblies. Tire and Wheel Removal and Installation

Transmission Fluid Cooler Inlet and Outlet Pipe Replacement — figure 56

80. Front Differential Carrier Oil Filler Plug (1) » Remove
81. Inspect the gear lubricant level, it should be 16–22 mm (0.6-0.9 in) below the plug opening.
82. If the level is low, add gear lubricant until the level is 16–22 mm (0.6-0.9 in) below the plug opening. Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

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

84. Front Stabilizer Shaft (1) » Install

85. Front Stabilizer Shaft Link Nut - Upper (1) @ Front Stabilizer Shaft » Install and tighten [2x] — Fastener Specifications

Note

The front stabilizer shaft insulator slit faces rearward.

Note

Support the front stabilizer shaft.

86. Front Stabilizer Shaft Insulator (3) » Install [2x]

87. Front Stabilizer Shaft Clamp (2) » Install [2x]

88. 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:

89. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.

90. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.

91. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers

92. Ensure there are no gaps in the thread locking adhesive once applied to the component.

93. Front Stabilizer Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

94. Underbody Skid Shield (2) » Install

95. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

96. Front Bumper Fascia Extension (4) » Install

97. If equipped, install the wire harness retainer.

98. Front Bumper Fascia Extension Bolt @ Skid Shield (3) » Install and tighten [2x] — Fastener Specifications

99. Front Bumper Fascia Extension Bolt (2) » Install and tighten [4x] — Fastener Specifications

100. Front Bumper Fascia Extension (1) » Install

101. Front Bumper Fascia Extension Bolt (2) » Install and tighten [8x] — Fastener Specifications

102. Front Bumper Fascia Air Deflector Bolt (1) » Install and tighten [10x] — Fastener Specifications

103. Lower the vehicle.

104. Install the condenser, fan, and radiator assembly (1). Condenser, Fan, and Radiator Assembly Removal and Installation

105. Check the transmission fluid level. Transmission Fluid Level and Condition Check