Removing and Installing Front Cardan Shaft

Removing and installing front cardan shaft

Tools

Preliminary work for front cardan shaft
1. Remove engine guard.

Removing front cardan shaft

Overview Of Carden Shaft:

Note:
^ To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
^ The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralise the residual imbalance of the components.

^ Apply another colour marking if necessary.

1. Remove cardan shaft from the transfer box-arrow-.

Note:
^ To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
^ The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralise the residual imbalance of the components.

^ Apply another colour marking if necessary.

2. Detach cardan shaft from final four wheel drive.

3. Support transmission with material 00000 and secure with retaining band.

4. Unscrew four exhaust system screws from cross member -centre arrow- and unscrew holder screws from body -right arrow-.

5. Unscrew transmission cross member bolts from body-A-.
6. Unscrew two screws fastening cross member-B-to transfer box support and remove transmission cross member.

7. Undo exhaust clamp on the right side-arrows- and push it in the direction of the catalytic converter.

Note: If the cardan shaft is to remain removed, the transmission cross-member must be refitted.

8. Remove cardan shaft between ATF pan and exhaust system support -arrow-.

Removing front cardan shaft

Note:
^ To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
^ The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralise the residual imbalance of the components.

^ Apply another colour marking if necessary.

1. Detach cardan shaft from final four wheel drive.

Note:
^ To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the foot brake.
^ The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralise the residual imbalance of the components.

^ Apply another colour marking if necessary.

2. Remove cardan shaft from the transfer box.
3. Swivel the cardan shaft forwards over the suspension subframe and remove it.

Installing front cardan shaft

Overview Of Carden Shaft:

Note:
^ The transmission cross member must be disassembled before the cardan shaft is installed.

1. Install cardan shaft between ATF pan and exhaust system support.

2. Fit new exhaust clamps -arrows-. The bolts must point downwards. Note tightening torque.
3. Support transmission with transmission jack.

Note:
^ Screws which are tightened with a torque angle must be replaced with new ones.

4. Screw in new screws fastening cross member-B- to transfer box support. Initial tightening: 37 ftlb. Final tightening: 90 degree angle

Note:
^ Screws which are tightened with a torque angle must be replaced with new ones.

5. Screw new cross member screws into body -A-. Initial tightening: 37 ftlb. Final tightening: 90 degree angle

6. Fasten exhaust system to transmission cross member -centre arrow- and body -outer arrow-. Observe torques for exhaust system.

Note:
^ The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralise the residual imbalance of the components.

Note:
^ To tighten the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the brake.

Note:
^ Screws which are tightened with a torque angle must be replaced with new ones.

7. Fix cardan shaft with new screws Front cardan shaft to all-wheel final drive to the all-wheel final drive. Initial tightening: 22 ftlb. Final tightening: 90 degree angle

8. Fix cardan shaft with new screws -arrow- to the transfer box. Initial tightening: 22 ftlb. Final tightening: 90 degree angle

Installing front cardan shaft

Note:
^ To tighten the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating the brake.
^ Screws which are tightened with a torque angle must be replaced with new ones.

2. Fix cardan shaft with new screws -arrow- to the transfer box. Initial tightening: 22 ftlb. Final tightening: 90 degree angle

3. Fix cardan shaft with new screws Cardan shaft to all-wheel final drive to the all-wheel final drive. Initial tightening: 22 ftlb. Final tightening: 90 degree angle

Subsequent work for front cardan shaft
1. Fit engine guard.