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Removal 1. Remove the differential carrier assembly. For additional information, refer to Differential Carrier in this section.2. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the 4 driveshaft flange bolts. 4. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. Using mechanic’s wire, position the driveshaft aside. 5. CAUTION: Discard the nut after removal. Use a new nut during installation. Use the special tool to hold the pinion flange while removing the drive pinion nut.6. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. 7. Using the special tool, remove the pinion flange. 8. Using a screwdriver, force up the rear axle drive pinion seal metal flange.9. Using gripping pliers and a hammer, remove the axle drive pinion seal. 10. Remove the axle drive pinion shaft oil slinger. 11. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer pinion bearing and remove it through the rear of the differential housing. 12. Remove the outer pinion bearing. 13. Remove the drive pinion collapsible spacer and discard it. 14. Using the special tool and a suitable press, remove the inner pinion bearing.

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Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the brake disc. For additional information, refer to Section 206-04. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

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1 – LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST 2 – DISC BRAKE CALIPER 3 – ADAPTER ABUTMENT 4 – OUTBOARD BRAKE SHOE HOLD DOWN CLIP 5 – OUTBOARD BRAKE SHOE 6 – ROTOR 7 – ADAPTER 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. See Fig. 22.1 – WIRE 2 – CALIPER 3 – ADAPTER 4 – ROTOR 5 – INNER FENDER 6. If the brake rotor needs to be removed it can be removed by removing the retainer clips and then pulling the rotor straight off the wheel mounting studs. 7. Remove the outboard brake shoe from the caliper. Brake shoe is removed by pushing the shoe toward the piston, disengaging the two metal protrusions on the shoe back, then sliding the brake shoe off the caliper.

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Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. Use care not to damage the filter mesh below the fluid surface. CAUTION: Locking the steering column in the straight-ahead position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. 3. Position the steering wheel in the STRAIGHT A HEAD position. Lock the steering wheel in place using a steering wheel holding tool. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler. Raise vehicle. Remove front wheel and tire assemblies. Remove front emissions vapor canister. Remove a single hose at power steering cooler and allow fluid to drain. 9. Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement. 10. On both sides of vehicle, remove nut attaching outer tie rod end to steering knuckle. Remove nut by holding tie rod end stud with a socket while loosening and removing nut with wrench. 11. Remove bolts fastening leak detection pump to cradle crossmember reinforcement. 12. Remove both outer tie rods from steering knuckles, using Puller, Special Tool C-3894-A. 13. Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes.

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1. Open hood. 2. Disconnect battery ground cable (14301). Refer to Section 14-01. 3. From inside vehicle, remove nuts retaining steering column tube boot (3C611) to cowl panel. 4. Remove bolt retaining steering column intermediate shaft coupling (3A525) to steering column lower yoke (3N725) . 5. Position steering column tube boot out of the way. Remove pinch bolt retaining steering column intermediate shaft coupling to power rack and pinion steering gear and remove steering column intermediate shaft coupling . 6. Raise vehicle on a twin post hoist and remove front wheel and tire assemblies. 7. Remove exhaust system flex tube-to-dual converter Y-pipe attachment. Disconnect heated oxygen sensor wiring harness. Remove dual converter Y pipe (5F250) from vehicle. Dual Converter Y Pipe Removal 8. Support vehicle with jack stands under rear edge of front sub-frame (5C145). 9. Remove tie rod cotter pins and nuts, and remove tie rod end (3A130) from RH front wheel knuckle (3K185) and LH front wheel knuckle (3K186). 10. Remove tie rod end from front wheel spindle tie rod (3280) . Mark position of jam nut to maintain alignment. 11. Remove nuts from steering gear-to-front sub-frame retaining bolts. 12. Remove rear sub-frame-to-body retaining bolts. 13. Raise twin post hoist carefully until rear sub-frame (5R003) separates from body approximately 102 mm (4 inches). 14. Remove heat shield push-pin retainers from power steering hose bracket (3C510). Remove steering shaft U-joint shield (3F540). 15. Remove screw and power steering left turn pressure hose (3A714) from power steering hose bracket . Remove two screws and power steering hose bracket. 16. Remove LH stabilizer bar link (5K484). 17. Disconnect power steering pressure switch electrical connector. 18. Rotate power rack and pinion steering gear to clear bolts from front sub-frame and pull left to ease line fitting removal. 19. Place a drain pan under vehicle and remove hydraulic power steering pressure hose and power steering return hose from fittings on power rack and pinion steering gear. 20. Remove power rack and pinion steering gear assembly through LH wheel well. Installation 1. Install new Teflon® O-rings on both line connector assemblies as described under Quick Connect Power Steering Fitting—Seal Replacement. 2. Place steering gear retaining bolts in steering gear housing (3548). 3. Install power rack and pinion steering gear through LH wheel well. 4. Install power steering hose bracket and two screws. Tighten to 9-12 Nm (80-106 lb-in). 5. Install hydraulic power steering pressure hose and power steering return hose to fittings on power rack and pinion steering gear. Tighten hoses to 33-41 Nm (25-30 lb-ft). 6. Install power steering pressure hose and and screw. Tighten to 9-12 Nm (80-106 lb-in). 7. Connect power steering pressure switch electrical connector. 8. Position power rack and pinion steering gear into front sub-frame. 9. Install tie rod ends onto front wheel spindle tie rods . 10. Install push-pin retainers at top of heat shield. 11. Install tie rod end to RHfront wheel knuckle and LH front wheel knuckle. Install nuts and tighten to 47-63 Nm (35-46 lb-ft). Install new cotter pins. 12. Install LH stabilizer bar link. Tighten to 76.5-103.5 Nm (57-76 lb-ft).