Front differential carrier — removal and installation
1. Disconnect the cable from the negative terminal of the battery (see Battery — disconnection and reconnection).
2. Loosen the front wheel lug nuts, raise the front of the vehicle and support it securely on jack stands placed under the frame rails. Remove the wheels.
3. Remove the differential carrier splash shield, if equipped.
Note: If you are removing the differential carrier to service other components, the fluid does not need to be drained.
4. Drain the lubricant from the front differential (see Differential lubricant change).
5. Remove the front driveshaft (see Driveshaft(s) — removal and installation).
6. Detach the vent hose from the differential housing.
7. Disconnect the electrical connector from the shift motor and disconnect the electrical harness from the carrier.
8.25-inch axle (LD)
8. Remove the steering gear (see Steering gear — removal and installation).
9. Remove the lower control arm crossmember.
10. Detach the inner ends of the drive axles from the axle shaft flanges (see Driveaxle (4WD models) — removal and installation). Suspend the drive axles with lengths of wire don’t let them hang by the outer CV joints.
11. Support the differential carrier with a floor jack. If a transmission jack adapter is available, use it — it will hold the assembly more securely.
12. Remove the two nuts that attach the axle tube (differential carrier) to the chassis.
13. Remove the differential carrier rear mounting bolts.
14. Pivot the differential carrier forward and down and slowly lowers the jack and guide the carrier out from under the vehicle.
15. Check the bushings in the front and rear mounting bosses; if they are in need of replacement, take the carrier to an automotive machine shop or other qualified repair facility to have the old bushings pressed out and the new ones pressed in.
16. Installation is the reverse of removal. Tighten all fasteners to the proper torque values. Refill the differential with the proper lubricant (see Tune-up and routine maintenance).
9.25-inch axle (HD)
17. Turn the steering wheel all the way to the left.
18. Remove the steering gear skid plate (if equipped).
19. Disconnect the relay rod from the idler arm and the Pitman arm (see Suspension and steering). Remove the tie-rod ends from the spindles and remove the relay rod.
20. Detach the inner ends of the drive axles from the axle shaft flanges (see Driveaxle (4WD models) — removal and installation). Suspend the drive axles with lengths of wire -don’t let them hang by the outer CV joints.
21. Support the differential carrier with a floor jack. If a transmission jack adapter is available, use it — it will hold the assembly more securely.
22. Remove the two nuts that attach the axle tube to the chassis.
23. Remove the differential carrier rear upper mounting bolt and nut.
24. Pivot the differential carrier down and away from the vehicle to access the lower mounting bolt and nut.
25. Slowly lower the jack and remove the lower mounting bolt. Guide the carrier out from under the vehicle.
26. Check the bushings in the front and rear mounting bosses; if they are in need of replacement, take the carrier to an automotive machine shop or other qualified repair facility to have the old bushings pressed out and the new ones pressed in.
27. Installation is the reverse of removal. Tighten all fasteners to the proper torque values. Refill the differential with the proper lubricant (see Tune-up and routine maintenance).