Clutch Cable Replacement

CLUTCH CABLE REPLACEMENT- Front Drive Axle

REMOVAL PROCEDURE
1. Remove the battery and the battery tray.
2. Remove the clutch cable hold down bolt attached to frame.





3. Disconnect the clutch cable from the retainer spring clip on the vacuum actuator.
4. Disconnect the clutch cable from the vacuum actuator bracket.
5. Raise the vehicle. Refer to Vehicle Lifting.
6. Remove the front differential carrier shield (if equipped).
7. Cut the strap holding the wire harness and the clutch cable together.





8. Disconnect the electrical connector from the four-wheel drive indicator switch.





9. Remove the three bolts from the clutch cable housing.





10. Separate the clutch cable housing from the differential carrier assembly.





11. Insert a screwdriver, or similar tool, into the clutch cable housing opening and disconnect the retainer spring from the clutch cable.





12. Remove the clutch cable and the clutch cable housing from the differential carrier assembly.





13. Disconnect the clutch cable coupling nut from the clutch cable housing.
14. Remove the clutch cable.

INSTALLATION PROCEDURE





1. Install the clutch cable housing.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the clutch cable housing bolts.
Tighten the clutch cable housing bolts to 48 Nm (36 ft. lbs.).




3. Insert the clutch cable into the clutch fork.
Engage the spring retainer in order to retain the clutch cable.
4. Install the clutch cable coupling nut to the clutch cable housing.
Tighten the clutch cable coupling nut to 10 Nm (89 inch lbs.).
5. Route the clutch cable to the vacuum actuator.
6. Connect the electrical connector to the four-wheel drive indicator switch.
7. Install the front differential carrier shield (if equipped).
8. Lower the vehicle.
9. Install the clutch cable hold down bolt.
Tighten the cable hold down bolt to 17 Nm (13 ft. lbs.).
10. Tie the cable and wire harness together with a tie strap.





11. Install the clutch cable to the vacuum actuator bracket.
The clutch cable must engage the retainer spring on the vacuum actuator.
The clutch cable lock tabs must engage the vacuum actuator bracket.
12. Install the battery and the battery tray.