D100 1/2 Ton Pickup 2WD V8-318 5.2L VIN Y FI (1988)
Axle Shaft: Service and Repair
Front Axle - Dana 44FBJ and 44-8FD
Axle Shaft Assembly
1. Disconnect battery ground cable, then secure brake pedal in the up position.
2. Raise and support vehicle, then disconnect front driveshaft at drive pinion yoke.
3. Disconnect drag link at steering knuckle arm (left side only).
4. Disconnect and plug brake line at frame crossmember.
5. Disconnect shock absorbers at lower mounts then disconnect sway bar link assembly, if equipped, from spring plates.
6. Disconnect vacuum lines and electrical connector from disconnect housing assembly if equipped.
7. Remove nuts and washers from U-bolt spring clips, then remove axle from vehicle.
8. Reverse procedure to install axle assembly. Lubricate all fittings, free brake pedal and bleed brakes.
9. Lower vehicle and check front wheel alignment.
Left Axle Shaft
REMOVAL
1. Raise and support vehicle.
2. Remove wheel and tire assembly.
3. Remove caliper retainer and anti-rattle spring assemblies.
4. Remove caliper from brake disc.
5. Hang caliper aside. Do not allow brake caliper to hang from brake lines.
6. Remove inboard brake shoe.
7. Remove brake disc, splash shield and spindle.
8. Disconnect vacuum lines and electrical connector from disconnect housing assembly switch.
9. Remove disconnect housing assembly from vehicle as previously described.
10. Remove intermediate axle shaft assembly. Carefully slide shaft through axle shaft seal to avoid damaging the seal assembly.
11. Using tool D-330 or equivalent, remove needle bearing from intermediate axle shaft.
12. Remove shift collar from axle housing.
13. Loosen, then remove differential cover attaching screws. Remove cover and drain lubricant.
14. Push inner axle shaft toward center of vehicle and remove C-lock from shaft groove recess.
15. Using tools D-354-4 and D-354-1 or equivalents, remove inner axle shaft bearing.
16. Remove outer axle shaft bearing and seal from housing bore.
INSTALLATION
1. Using tools D-354-4, D-354-2 and C-367 or equivalents, install inner axle shaft bearing.
2. Using a suitable tool, install inner axle shaft. Install C-lock into axle shaft groove recess.
3. Install shift collar on splined end of inner axle shaft.
4. Install axle shaft bearing and seal.
5. Install needle bearing into intermediate axle shaft.
6. Install intermediate axle shaft through seal.
7. Install disconnect housing assembly and gasket as previously described.
8. Install disconnect housing assembly shield and bolts. Tighten bolts to specification.
9. Connect vacuum lines and electrical connectors to switch assembly.
10. Install splash shield and spindle. Tighten nuts to specification.
11. Install brake disc, outer bearing, nut, washer and locknut on spindle assembly.
12. Install spring retainer, spring, drive gear and drive gear snap ring.
13. Apply RTV sealant to seating edge of grease cap, then install the cap.
14. Position inboard brake shoe on adapter with shoe flanges in adapter keyways. Slowly slide caliper assembly into position in adapter and over brake
disc.
15. Install anti-rattle springs and retaining clips. Tighten to specification.
16. Apply a 1/16 inch bead of suitable sealant along bolt circle of cover.
17. Allow sealant to cure and install on axle. Tighten attaching bolts to specification.
18. Remove fill plug and fill axle with suitable lubricant.
19. Install tire and wheel assembly.
Right Axle Shaft
REMOVAL
1. Raise and support vehicle.
2. Remove wheel and tire assembly.
3. Remove caliper retainer and anti-rattle spring assemblies.
4. Remove caliper from brake disc. Hang caliper aside. Do not allow caliper to hang from brake lines.
