Tools and Materials Needed:
- Jack stands
- Socket set
- Wrenches
- Ball joint separator
- Bearing press or suitable tools
- New bearings (inner and outer)
- New seals
- Replacement axle shafts (optional, if needed)
- Grease
- Locktite (thread locker)
Steps:
1. Preparation:
- Safely raise and support the front end of the CJ5 using jack stands.
- Remove the front wheels.
2. Disconnect Tie Rod:
- Disconnect the tie rod from the steering knuckles by removing the cotter pin and nut holding the tie rod to the steering arm. Tap the tie rod end out with a hammer if needed.
3. Remove Ball Joints:
- Remove the cotter pin and nut holding the ball joint to the steering knuckle spindle, then separate the ball joint from the steering knuckle using a ball joint separator.
- Be careful not to damage the ball joint boot.
4. Pull Axle Shafts:
- Slide off the brake caliper and temporarily secure it to the side (avoid stretching brake lines).
- Remove the brake rotor by removing the bolts holding it to the hub.
- Remove the spindle nut (large nut securing the hub bearing to the spindle). Some axle shafts may have the spindle nut installed backwards, so be sure to check how it is seated.
- With the nut removed, use gentle prying or puller tools to remove the hub and bearing assembly from the axle. The hub assembly may be snug - a hub puller may be required.
- The outer (wheel-end) bearing should separate from the hub when removed. Check for any damage or wear on the old bearings and replace if necessary.
- Inspect the axle shaft as well and replace if needed.
5. Remove Inner Bearing and Seal:
- With the hub and bearing assembly removed, remove the inner bearing and seal from the axle housing using a suitable bearing puller or by drifting it out.
6. Clean and Inspect:
- Clean the axle housing and spindle thoroughly removing any debris, grease, or old sealant. Inspect the spindle for wear or damage. Replace if necessary.
7. Install New Seal:
- Apply thread sealant (Locktite) to the threads of the seal and carefully screw the new inner seal into place in the axle housing. Ensure it is seated fully and evenly.
8. Install New Bearing:
- Pack the new inner bearing with high-temperature bearing grease.
- Using a suitable tool or bearing press, press the new inner bearing onto the spindle until it reaches the shoulder of the spindle. Check that the bearing sits squarely and flush.
9. Reassemble:
- Install the new outer bearing into the hub assembly, making sure to apply grease.
- Slide the hub assembly back onto the spindle, ensuring the outer bearing is seated correctly against the inner bearing.
- Install and tighten the spindle nut ensuring it is sufficiently tight, using a torque wrench if available.
- Reattach the brake rotor and caliper.
10. Reattach Ball Joints and Tie Rod:
- Re-install the ball joints and steering knuckles, securing them with new nuts and cotter pins.
- Reattach the tie rod to the steering arm and secure with a new nut and cotter pin.
11. Finalize:
- Check for any loose components or bolts. Apply grease to the ball joints and tie rod ends.
- Reinstall the wheels and lower the vehicle.
- Top up any fluids (e.g., differential oil) as needed.
- Test drive carefully and listen for any unusual noises or vibrations.
Note: If the axle shafts were replaced or there were significant changes made, you may need to perform a front-end alignment to ensure proper steering and handling. Consult with a qualified mechanic or alignment specialist if needed.
