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REMOVAL & INSTALLATIONHalfshaft Without the DOJ Case
See Figure 1
Fig. 1: Exploded view of the right side halfshaft assembly (left halfshaft similar)-If the DOJ case does not need to be removed, the halfshaft can be removed without lowering the front axle assembly
If the DOJ case does not require servicing, as is the case with outer CV-joint servicing or inner CV-joint overhaul, use this procedure. The halfshaft, with the exception of the DOJ case, can be removed without removing the entire front axle assembly.
Entire Halfshaft Assembly, Bearing and Seal
If the entire halfshaft (including the DOJ case) must be removed from the vehicle, the entire front axle assembly should be removed from the vehicle for ease of disassembly, since the mounting brackets for the axle assembly are also the halfshaft-to-differential mounting brackets. These brackets must be unfastened to remove the inner DOJ case from the assembly.
1981-87 PICK-UP AND 1985-87 TROOPER MODELS
See Figure 2
Fig. 2: Front axle assembly on all 1981-95 models
Before installing the axle shaft bearing, lightly lubricate the bearing with differential lube.
1988-95 TROOPER AND PICK-UP, 1989-94 AMIGO AND 1991-95 RODEO MODELS
See Figures 1 and 2
The right axle shaft is an integral part of the right halfshaft assembly. Removal of the left axle shaft involves disassembling the shift-on-the-fly four-wheel drive gearbox. The inboard joints of both halfshafts fit through the axle mounting brackets, which are bolted to the axle housing, therefore the axle housing should be removed from the vehicle for ease of disassembly.
WARNING Be careful not to damage the CV-joints, boots, or splined shafts when removing the axle.
Use new self-locking nuts and color-coded bolts when assembling the axle assembly mounts and suspension components. Suspension fasteners should be tightened to their final torque specifications when the vehicle is on the ground.