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Workman HDX/HDX−D Page 10 − 13 Front Wheel Drive (4WD)
Removal (Fig. 8)
1. Park vehicle on a level surface, shut engine off, re-
move key from ignition switch and apply parking brake.
Block rear wheels to prevent the vehicle from moving
unexpectedly.
2. Drain differential oil into a suitable container by re-
moving the drain plug. Install drain plug after draining.
3. Unplug wire harness connector from differential.
4. Remove both CV axle assemblies from the differen-
tial (see CV Axle Assembly Removal in this section).
5. Remove cap screw and flat washer that secure dri-
veshaft yoke to the differential input shaft. Separate dif-
ferential driveshaft yoke from the differential input shaft
(see Differential Driveshaft Removal in this section).
CAUTION
Support differential during removal to prevent
personal injury from falling and damage to the
differential.
6. Remove four (4) flange head screws that secure the
differential to the frame.
7. On right side (passenger side) of vehicle, remove in-
ner two (2) flange head screws and flange nuts that se-
cure control arm tower to upper control arm (Fig. 9).
Removal of these two (2) fasteners allows clearance for
differential removal. To prevent unexpected front sus-
pension movement, do not loosen outer flange head
screws and flange nuts.
IMPORTANT: Make sure to not damage brake lines,
electrical harness, control cables or other parts
while removing the differential.
8. Tip differential toward left side (driver side) of ve-
hicle. Remove differential assembly toward the right
side (passenger side) of the vehicle.
Installation (Fig. 8)
IMPORTANT: Make sure to not damage brake lines,
electrical harness, control cables or other parts
while installing the differential to the vehicle.
1. Position differential to the vehicle frame.
2. Secure differential to the frame with four (4) flange
head screws.
3. Install and tighten inner two (2) flange head screws
and flange nuts that secure control arm tower to upper
control arm (Fig. 9).
4. Apply antiseize lubricant to input shaft of differential.
Slide driveshaft yoke onto differential input shaft.
5. Secure driveshaft yoke to the differential with cap
screw and flat washer (see Differential Driveshaft Instal-
lation in this section).
6. Install both CV axles to the differential (see CV Axle
Assembly Installation in this section).
7. Connect wire harness connector to differential.
8. Make sure differential drain plug is installed properly.
Fill differential with oil.
1. Upper RH control arm
2. Inner screw and nut
3. Differential
4. Outer screw and nut
Figure 9
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3
2
4
Front Wheel
Drive (4WD)