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 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 color markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralize the residual imbalance of the components.

^ Apply another color marking if necessary. Match points of front cardan shaft to front final drive

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

Fastening of cardan shaft to transfer box

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 color markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralize the residual imbalance of the components.

^ Apply another color marking if necessary. Match points of

front cardan shaft to front final drive

2. Detach cardan shaft from final four wheel drive ->Front cardan shaft to all-wheel final drive.
Front cardan shaft to all-wheel final drive
3. Support transmission with material transmission jack 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-.

Exhaust system at cross member

5. Unscrew transmission cross member bolts from body-A-.

Transmission cross member

6. Unscrew two screws fastening cross member-B-to transfer box support and remove transmission crossmember.

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

Exhaust clamp

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 color markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralize the residual imbalance of the components.

^ Apply another color marking if necessary.
Match points of front cardan shaft to front final drive

1. Detach cardan shaft from final four wheel drive ->Front cardan shaft to all-wheel final drive.

Front cardan shaft to all-wheel final 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 color markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralize the residual imbalance of the components.

^ Apply another color marking if necessary. Match points of front cardan shaft to front final drive

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

Installing front cardan shaft

Overview of cardan 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. ->260119 Removing and installing exhaust system'
Exhaust clamp
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 ft. lbs. Final tightening 90° angle
Transmission cross member

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 ft. lbs. Final tightening 90° angle

6. Fasten exhaust system to transmission cross member -centre arrow- and body -outer arrow-. Observe torques for exhaust system ->260119 Removing and installing exhaust system'

Exhaust system at cross member

Note: The color markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must be aligned. This will neutralize the residual imbalance of the components. Match points of front cardan shaft to front final drive

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 ft. lbs. Final tightening 90° angle

Front cardan shaft to all-wheel final drive

8. Fix cardan shaft with new screws -arrow- to the transfer box. Initial tightening 22 ft. lbs. Final tightening 90° angle

Front cardan shaft to transfer box

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 ft. lbs. Final tightening 90° angle

Front cardan shaft to transfer box

3. Fix cardan shaft with new screws ->Cardan shaft to all-wheel final drive to the all-wheel final drive. Initial tightening 22 ft. lbs. Final tightening 90° angle
Cardan shaft to all-wheel final drive

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