Intermediate Shaft, Outer Axle Shaft & Shift Housing, Replace

Models W/Select Drive System
1. Raise and support front of vehicle.
2. Remove front axle assembly, then drain lubricant.
3. Remove bolts securing shift housing and remove shift fork, shifting housing and shift motor as an assembly.
4. Working through access hole in the outer axle shaft flange, remove screws securing axle tube cover.
5. Remove outer axle shaft assembly by tapping shaft flange with a rubber or plastic mallet.
6. Remove intermediate shaft snap ring, then remove intermediate shaft and shift collar.
7. Using a suitable puller and slide hammer, remove outer axle shaft bearing race.
8. Using adapter tool No. J-26225 and slide hammer J-6471-2, remove intermediate shaft needle bearing from axle tube end.
9. Using spreader tool No. J-29369-1 and slide hammer No. J-2619-01, remove intermediate shaft gear bearing. The intermediate shaft gear is retained on the axle shaft by an internal type expandable snap ring. When removing the bearing from the gear be sure to support the gear face on vise jaws to avoid pulling the gear off the shaft. The gear and shaft are serviced only as an assembly.
10. Remove outer axle shaft retaining E-ring.
11. Make a reference mark on outer axle shaft gear (for assembly purposes) and remove gear from shaft.
12. Remove outer axle shaft bearing using an arbor press.
13. Remove axle oil seal and tube cover.
14. Clean and carefully inspect all components for wear or damage. Replace all necessary components.
15. Install axle oil seal and tube cover on axle shaft.
16. Using an arbor press, install axle shaft bearing and race on shaft.
17. Install axle shaft gear on shaft using an arbor press. Be sure to align reference mark. Also ensure gear splines are facing outward.
18. Install axle shaft E-ring.
19. Using tool No. J-29153, install intermediate shaft needle bearing.
20. Install intermediate shaft gear needle bearing in gear bore using an arbor press.
21. Install intermediate shaft, then install shift collar, and seat shaft in differential.
22. Install intermediate shaft lock ring.
23. Install outer axle shaft assembly, torque axle tube cover bolts evenly and in a cross sequence. Torque bolts 144 inch pounds.
24. Install gasket on shift housing cover and install. Check to ensure the shift fork and tabs are aligned in the shift collar.
25. Torque shift housing cover bolts to 108 inch pounds.
26. Install axle cover using a new gasket. Torque bolts to 20 ft. lbs.
27. Fill shift housing with five oz.. of specified lubricant, then fill axle housing.