Dismantling
1. Put the car on a lift.
2. Disconnect the negative plug from the storage battery.
3. Remove the air tube.
HEATING AND VENTILATION, REPAIR WORKS, Air filter - air intake.
4. Remove the viscous coupling with the fan.
COOLING SYSTEM: V8 engine, REPAIR WORK, Viscous fan clutch.
5. Install a container under the hydraulic booster reservoir, disconnect the pipeline and drain the working fluid. Close the openings of the connections with plugs.
6. Discard the power steering pipe O-ring.
7. Remove the two engine mount nuts.
8. Attach the chain to the engine mounting brackets and tension the chain with the weight of the engine.
9. Drain the oil from the final drive housing.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, ADJUSTMENTS, Front final drive and differential housing - oil drain and fill.
10. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
11. Remove the seal from the inner end of the right drive shaft.
DRIVE SHAFTS, REPAIR WORKS, Seal - drive shaft - front - right.
12. Remove the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
13. Turn out the Torx screw of the lower hinge of a steering shaft.
14. Turn the steering wheel to the straight ahead position, align the marks on the steering gear shaft and remove the ignition key.
CAUTION: Do not turn the steering wheel while the intermediate shaft or universal joint is disconnected as this will damage the rotary slip ring and steering wheel controls.
15. Disconnect the steering shaft from the gear shaft.
16. Mark position of clips and remove clips of fastening to a stretcher of cables of sensors of position of a body and gauges.
17. Remove blocks from electric sockets of gauges of provision of a body.
18. Remove the steering shaft angle sensor connector block.
19. Remove the 2 nuts securing each anti-roll bar heat shield to the body and 2 screws securing each heat shield to the subframe. Remove heat shields.
20. Use a jack to support the subframe.
21. Turn out 6 screws of fastening of a stretcher. Remove the 2 screws securing the subframe to the cross frame (indicated by arrows).
22. Together with an assistant, lower and remove the subframe assembly.
23. Remove the ventilation hose of the final drive case. Remove the 4 screws securing the final drive housing and, with the help of an assistant, remove the final drive assembly. Remove and discard the O-ring.
NOTE: The mounting screw located above the final drive gear must remain in the final drive housing.
Assembly
1. Clean the final drive housing and all mating surfaces.
2. Install a new O-ring in the final drive housing and lubricate it with petroleum jelly.
3. With the help of an assistant, carefully install the final drive assembly. Tighten the fastening screws with a torque of 102 Nm.
4. Attach a ventilating hose to a case of the main transfer.
5. Clean the mating surfaces of the subframe and car body.
6. Install the subframe assembly with an assistant.
7. Tighten the 6 screws securing the subframe to the body with a torque of 165 Nm. Tighten the 2 rear screws another 90°.
8. Tighten the 2 screws securing the subframe to the transverse frame with a torque of 132.5 Nm.
9. Install the anti-roll bar heat shields and tighten the 2 bolts and nuts.
10. Lower the engine onto stands.
11. Tighten the nuts securing the engine brackets to the supports with a tightening torque of 100 Nm.
12. Connect block to a socket of the gauge of an angle of rotation of a steering shaft.
13. Attach blocks of electric sockets of forward gauges of vertical position of a body.
14. Route the sensor cables and secure them with the clamps in their original position.
15. Clean the power steering pump and pipe union.
16. Install a new sealing ring on the high pressure pipe tip, connect the pipe to the pump and tighten the union nut to a torque of 25 Nm.
17. Check the alignment of the mounting marks and attach the steering shaft to the shaft of the steering gearbox. Install a new steering shaft pivot screw and tighten to 24 Nm.
18. Install differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
19. Install the right drive shaft seal.
DRIVE SHAFTS, REPAIR WORKS, Seal - drive shaft - front - right.
20. Reinstall the front propeller shaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
21. Fill oil into the final drive housing to the required level.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, ADJUSTMENTS, Front final drive and differential housing - oil drain and fill.
22. Install the viscous fan clutch.
COOLING SYSTEM: V8 engine, REPAIR WORK, Viscous fan clutch.
23. Replace the air tube.
HEATING AND VENTILATION, REPAIR WORKS, Air filter - air intake.
24. Connect the negative terminal to the battery.
25. Remove air from the system and add working fluid to the hydraulic booster reservoir.
STEERING, ADJUSTMENTS, Power Steering (PAS) - removal of air.
26. Check and, if necessary, adjust the slip of the front wheels.
STEERING, ADJUSTMENTS, Front wheel alignment - check and adjustment.
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