Removal Procedure
Drivetrain and Front Suspension Cradle (1) - Remove - Drivetrain and Front Suspension Cradle Removal and Installation (AWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (FWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (Z71)
- Drain the power transfer unit case fluid. Power Transfer Unit Case Fluid Replacement
Disconnect the electrical connector.
- The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
- Using an appropriate tool, remove the heated oxygen sensor (1).
- NOTE:
Using a combination ratcheting wrench may be helpful for bolt access.
Turbocharger Heat Shield Bolt (1) - Remove [4x]
Catalytic Converter Front Heat Shield- Outer (1) - Remove
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Catalytic Converter Front Heat Shield- Inner (1) - Remove
Warm Up Three-Way Catalytic Converter Nut. (1) - Remove [4x]
Disconnect the electrical connector.
Catalytic Converter Brace Bracket Bolt (1) - Remove [2x]
- NOTE:
Remove the warm up three-way catalytic converter from the bottom of the vehicle.
Warm Up Three-Way Catalytic Converter (1) - Remove
- Turbocharger Exhaust Pipe Gasket (2) - Remove and DISCARD
- NOTE:
Some components not shown for graphic clarity.
Power Transfer Unit Heat Shield Bolt (1) - Remove [3x]
- Power Transfer Unit Heat Shield (2) - Remove
- Have an assistant apply the brakes.
- WARNING:
To prevent personal injury and / or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft (s) or wheel drive shaft nut (s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.
CAUTION:DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut (1) - Remove and DISCARD
Attach the DT-45859 Axle Remover (1) to the front wheel hub using the wheel nuts (2).
- Using the DT-45859 Axle Remover (1), separate the front wheel drive half shaft from the front wheel hub.
- Remove the wheel nuts (2) and the DT-45859 Axle Remover (1) from the front wheel hub.
- CAUTION:
Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft (s). Damage to the boot (s), the seal (s) or the clamp (s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.
Use a suitable flat bladed tool (1) to dislodge the front wheel drive half shaft (2) from the power transfer unit.
Front Wheel Drive Half Shaft (1) - Remove
Front Wheel Drive Shaft Washer (1) @ Front Wheel Drive Half Shaft - Remove and DISCARD
Front Wheel Drive Shaft Retaining Ring (1) - Remove and DISCARD
- Power Transfer Unit Half Shaft Seal (2) - Remove and DISCARD
Transfer Case Bracket Bolt (1) - Remove [3x]
- Transfer Case Bracket Bolt (2) - Remove [2x]
- Transfer Case Bracket (3) - Remove
- Disconnect the shift actuator electrical connector.
Power Transfer Unit Bolt (1) - Remove [2x]
- Support the transfer case with a suitable jack, and secure with suitable straps.
Disconnect the transfer case vent hose (1) from the transfer case (2).
Power Transfer Unit Bolt (1) - Remove [3x]
- Separate the transfer case (2) from the transmission and remove the transfer case.
Power Transfer Unit Interface Seal (1) - Remove and DISCARD
Refer to Heated Oxygen and Oxygen Sensor Caution .
The use of excessive force may damage the threads in the exhaust manifold / pipe.