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Remove the Differential

Prep the front differential for removal. A floor jack or a very strong buddy is highly recommended!

A picture is not available for this step, but it’s not hard to do. Disconnect the electric, vacuum, and breather lines from the front differential. Some of them are held on with a bolt and bracket on the top of the differential. The electrical is clipped on with a wire harness.

Using a 12mm allen wrench, remove the rear mount bolt and bracket (from the front differential).

14aPut the floor jack under the differential pumpkin (red arrow). Remove the two front differential mounting bolts (yellow arrows).

Once they are removed, the differential will only be supported by the jack (and maybe the rear mounting bracket). The differential will want to fall to the passenger side because the jack isn’t centered underneath. Don’t let this happen. Slowly lower the differential to the floor while double checking that you have removed every electric, vacuum, and breather line that may be attached to it. In fact, if you are unable to disconnect the electric, vacuum, and breather lines (as mentioned above), then lowering it a few inches will make that task a lot easier.

IMPORTANT: Use care not to damage the 4WD actuator vacuum assembly (ADD models) when lowering the differential.

Take the nuts, bolts, washers, spacers, and rear differential bracket and put them in a zip-loc bag and label it ‘DIFFERENTIAL’. Put the bag in a in a safe place because you will reuse these parts for reassembly.

14bThe differential looks like this when removed. Remove the two front differential mounting brackets (yellow arrows). One is held on with three bolts and the other with two. Save the bolts and discard the brackets.

Locate the two Fabtech front differential brackets. Install the four half bushings and two bushing sleeves into the brackets. Using the factory hardware, install the Fabtech brackets onto the differential. Use Loc-Tite and torque the bolts to 70 foot pounds.

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