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1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-00. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-00. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the Specifications in this section. Item 2: Rear Disc Brake Caliper Removal Note 1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support. Position the rear disc brake caliper aside. For additional information, refer to Section 206-00. Item 7: Differential Pinion Shaft Removal Note 1. Move the differential pinion shaft out far enough to remove the U-washers. Replace the shaft and install the lock bolt finger tight when U-washers are removed. Item 8: U-washer Removal Note 1. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal Note 1. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 8.8 inch rear axle, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 9.75 inch and the 10.25 inch rear axles, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. Item 11: Axle Shaft Bearing Installation Note 1. For the 8.8 inch and the 9.75 inch rear axles, use the special tools to install the rear axle wheel bearing. 2. For the 10.25 inch rear axle, use the special tools shown to install the rear axle wheel bearing. Item 10: Wheel Bearing Oil Seal Installation Note 1. Use the special tools shown to install the rear wheel bearing oil seal. Item 8: U-washer Installation Note 1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1. Position the two U-washers on the button end of the axle shafts. 2. Pull the axle shafts outward.

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CAUTION: Use of incompatible bearing lubricant could result in premature lubricant breakdown. The recommended wheel bearing lubricant is the lithium-base grease High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, before lubricating front or rear wheel bearings (1225), thoroughly clean all old grease from the bearing and front disc brake hub and rotor (1102). If bearing adjustment does not eliminate looseness or rough and noisy operation, clean and inspect the front disc brake hub and rotor and bearings. If bearing cups or the cone and roller assemblies are worn or damaged, replace. Disassembly 1. Raise vehicle and install safety stands. 2. Remove the wheel and tire. Refer to Section 04-04 in the Body, Chassis Manual. 3. Remove the locking hubs. 4. CAUTION: Do not let the disc brake caliper (2B120) hang only by the hose, or damage might occur to the hose or disc brake caliper. Remove the disc brake caliper. Refer to Section 06-03 in the Body, Chassis manual. Securely wire the disc brake caliper to the frame. 5. For vehicles equipped with automatic locking hubs, remove C-ring or snap ring and three-piece thrust washers (spacers). Remove the cam assembly and wheel bearing nut retaining key. Remove wheel bearing retainer (nut) using Hub Nut Wrench T95T-1197-B. Repack the wheel bearings with the specified lubricant (grease). For vehicles with manual locking hubs, remove snap ring, three-piece thrust washers (spacers), the outer lock nut, lockwasher, and inner lock nut using Spanner Locknut Wrench D85T- 1197-A or equivalent. 6. Remove the front disc brake hub and rotor. The front outer wheel bearing will slide out as the hub is removed. 7. Remove the retaining nuts of the front wheel spindle (3105). Carefully remove the front wheel spindle from the knuckle studs and halfshaft (3A329). If necessary, lightly tap the end of the spindle with a rawhide hammer to remove. 8. Clean old grease from the needle bearings and the bore seal of the front wheel spindle. To replace spindle bearing or inner seal, refer to Section 05-03A or Section 05-03B. 9. Clean any old grease or dirt from these parts and replace if signs of excessive wear are noted. Assembly 1. Using High-Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A, thoroughly lubricate the needle bearing and coat the front wheel spindles or face that mates with the seals of the front wheel spindle. 2. Assemble the front wheel spindle over the halfshaft onto the knuckle studs. Tighten the retaining nuts to 68-81 Nm (50-60 lb-ft). 3. Remove the front inner wheel bearing, wheel hub grease seal (1190) from the front disc brake hub and rotor using Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T50T-100-A. Inspect bearings and replace as necessary. 4. Inspect the bearing cups for pits or cracks. If necessary, remove with a drift. If new cups are installed, install new cones and rollers. 5. Lubricate the bearings with High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford Specification ESA-M1C198-A. Clean all old grease from the front disc brake hub and rotor. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 6. Position the front inner wheel bearing in the inner cup and install the new wheel hub grease seal using a hammer, Driver Handle T80T-4000-W and the proper seal installer.

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Front Axle Will Not Disengage Circuit Description The front axle control circuit consists of an electric motor actuator which engages and disengages the front axle. The front axle actuator motor consists of a permanent magnetic motor, a worm gear controlled plunger, a front axle switch and an electronic control circuit all within the actuator assembly. The front axle actuator consists of the following circuits: The front axle control circuit, which is also connected to the transfer case shift control module The front axle switch circuit, which is also connected to the transfer case shift control module A battery feed circuit A ground circuit When a shift to AUTO 4WD, 4HI or 4LO is requested, the transfer case shift control module engages the front axle by grounding the front axle control circuit through a current limiting driver. Diagnostic Aids A mechanical condition inside the front axle could prevent the shift fork from moving causing the motor to be stuck in one position. Refer to Symptoms – Front Drive Axle See: Differential Assembly\Testing and Inspection\Symptom Related Diagnostic Procedures\Diagnosis By Symptom – Front Drive Axle\- Symptoms – Front Drive Axle

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Models: 1988-97 Chevrolet and GMC K Models excluding 1988-93 Models over 8500 # GVW This bulletin is being revised to add information to the Service Procedure, add a new part number, and include schematics. Please discard Corporate Bulletin Number 76-43-01 (Section 4 – Drive Axle). Condition Some owners may comment that the Colder the outside temperature is, the longer it takes for the front axle to engage when 4 wheel drive is selected, or the front axle does not engage. Cause The front axle engagement actuator is a thermally activated component. Because of this characteristic, the time required for the actuator to complete 4 wheel drive engagement is extended as the temperature drops. Correction Replace the front axle actuator and include the applicable wiring harness kit. Refer to the Parts Information in order to determine which wiring harness kit is needed. 1996 model trucks with a build date on or after January 2, 1996 are considered as “961″. If the build date of the truck is unknown, verify the 3 character “axle code” on the front axle label in order to determine which wire harness to order. This new actuator uses a motor to engage the front axle and is not affected by temperature. On 1988-93 models with a GVW rating over 8500$, the new actuator cannot be installed and the thermal actuator will remain the service part

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1. Raise and support vehicle, then remove tire and wheel assembly. 2. Install a brass drift or a screwdriver to prevent the rotor from turning, Fig. 7 . 3. Remove axle nut and washer. 4. Remove stabilizer shaft or link from control arm. 5. Remove nut from ball joint, then separate ball joint from steering knuckle using separator tool No. J-36226, or equivalent. 6. Remove drive axle from hub and bearing assembly using front hub spindle remover tool No. J-28733-A, or equivalent, Fig. 8 . 7. Remove drive axle from transaxle using axle shaft remover puller tool Nos. J-33008, J-29794 and slide hammer tool No. J-2619-01, or equivalents, if necessary, Fig. 9 . INSTALLATION 1. Install drive axle into the transaxle using seal protector J-37292-B, or equivalent 2. Seat snap ring by placing a screwdriver into the groove on the joint housing and tapping until seated, Fig. 9 . 3. Grasp the inner housing and pull outward. If the snap ring is properly seated, the axle will remain in place. 4. Install drive axle into hub and bearing assembly. 5. Install lower ball joint to steering knuckle and tighten to specifications. 6. Install stabilizer shaft or link to control arm, tighten to specifications. 7. Insert a screwdriver or drift into caliper and rotor to prevent rotor from turning, Fig. 7 . 8. Install new hub nut and washer, tighten to specification. 9. Install tire and wheel assembly, then lower vehicle