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.
If equipped with 4-wheel drive, shift the transfer case shift lever into 2H. Drive the vehicle a few feet forward and reverse to verify that the front axle is disengaged.
Set the front wheels and steering wheel in the straight-ahead position. Lock the steering column in this position, and remove the key.
Apply the parking brake and block the rear wheels.
Raise and safely support the front of the vehicle on jackstands.
Remove the front wheels and underside skid plate.
Remove the front brake calipers and caliper mounting brackets. Do not disconnect the brake line. Hang the brake calipers from a wire, do not allow the calipers to hang from the brake hoses. For more information, refer to Brakes .
Remove the locking hub assembly and rotors on both sides, as described earlier in this section.
If equipped with ABS, unbolt the front wheel sensor brackets from the steering knuckles. Move the sensors out of the work area. They do not need to be disconnected.
Use a ball joint separator tool to disconnect the upper and lower ball joints and tie rod ends, and then remove the steering knuckles.
If necessary for added clearance, matchmark and disconnect the pitman arm and idler arm. Remove the steering linkage as an assembly.
Remove the inner CV-joint boot clamp, then slide the boot away from the joint. To remove the clamp, it may be necessary to pry the hooked end of the clamp up with a small prytool.
Remove the circlip from the DOJ case, then pull the halfshaft away from the DOJ case.
Remove the halfshaft from the vehicle.
To install:
If the halfshaft was not overhauled, clean the DOJ joint of all dirt and grease, then fill the inner boot and DOJ with 5.25 oz. (150g) new grease. Install the halfshaft into the DOJ case and install the circular clip into the groove so the open ends are positioned away from the ball groove.
Slide the boot onto the DOJ case, insert a tool under the boot lip to allow the pressure to equalize and tighten the new boot clamps. The boot should be installed so the edge of the smaller end is 6.5 in. (16.5cm) from the opposite edge of the DOJ case.
Install the steering knuckles and assemble any suspension components that were disconnected or removed.
Install the rotor and hub assemblies, as described earlier in this section.
Install the caliper mounting brackets and the brake calipers. For more information, refer to Brakes .
If necessary, install the steering linkage assembly.
If equipped, reconnect the ABS front wheel sensors.
Install the radiator skid plate. Tighten the bolts to 58 ft. lbs. (78 Nm).
Install the transfer case skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
Install the front wheels.
Lower the vehicle, remove the rear wheel blocks and adjust the ride height.
If the steering linkage was removed, have the front wheel alignment checked by a reputable automotive technician.
If necessary, bleed the brake system.
Verify that the front axle and hubs engage and disengage properly.
Road test the vehicle.
