Installation Procedure
- Fuel Level Sensor (1) - Install
- Engage the retaining tabs.
- Connect the electrical connector.
Fuel Pump Seal (2) - Install NEW
- Fuel Tank Fuel Pump Module (1) - Install
Transfer Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Vent Hose (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector (1) - Connect
Fuel Sender Ring (1) - Install - CH-45722 Fuel Sender Lock Ring Wrench (2)
Evaporative Emission Canister Hose (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Evaporative Emission Valve Hose (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Pump Fuel Feed Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector (1) - Connect [3x]
With aid of an assistant, remove tank from bench and place on a suitable adjustable jack.
- When raising tank guide fuel tank filler hose into fuel tank filler pipe.
- Fuel Tank (1) - Install
Fuel Tank Strap (3) - Install [2x]
- Fuel Tank Strap Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Fuel Tank Strap Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Remove the adjustable jack from under the fuel tank.
Evaporative Emission Canister Purge Hose (6) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Vent Hose (5) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Evaporative Emission Valve Hose (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Hose Clamp (2) - Tighten - Fastener Specifications
- Fuel Tank Filler Pipe Ground Bolt (1) - Install and tighten - Fastener Specifications
Fuel Pump Fuel Feed Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Vent Valve Hose (1) - Connect - Plastic Collar Quick Connect Fitting Service
Wiring Harness Connector (1) - Connect [2x]
- Install wiring harness retainers.
Fuel Tank Shield (2) - Install
- Fuel Tank Shield Retainer (1) - Install [5x]
Apply a thin layer of grease to the transmission output shaft splines (1). Adhesives, Fluids, Lubricants, and Sealers
- Loosely install a NEW propeller shaft hub clamp (3) to the propeller shaft joint boot.
- Support and secure the propeller shaft (2) to a suitable hydraulic jack stand.
- Propeller Shaft (2) - Install
Prepare the 2 propeller shaft bearing support bolts (1) for installation as follows:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Propeller Shaft Bearing Support Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Remove the hydraulic jack stand supporting the propeller shaft.
Prepare the 3 rear propeller shaft bolts (1) and nuts (3) for installation as follows:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Align the relationship marks (2) made on the propeller shaft and the rear differential flange.
- Rear Propeller Shaft Bolt (1) - Install [3x]
- Rear Propeller Shaft Nut (3) - Loosely install [3x]
- Rear Propeller Shaft Bolt (1) - Tighten [3x] - Fastener Specifications
Using a suitable jack stand, support the rear of the transmission.
- Transmission Mount Bracket Bolt (1) - Remove [4x]
Transmission Mount Bolt (1) - Remove [2x]
- Transmission Mount (2) - Remove
Ensure that the drive shaft boot is completely seated in the output shaft groove prior to crimping the propeller shaft hub clamp (2).
- Using the DT-35910 Drive Axle Seal Clamp Pliers (1), crimp the propeller shaft hub clamp (2) until the final crimped outer diameter (a) is 39 - 41 mm (1.54 - 1.61 in).
Transmission Mount (2) - Install
- Transmission Mount Bolt (1) - Loosely install [2x]
Transmission Mount Bracket Bolt (1) - Loosely install [4x]
Transmission Mount Bolt (1) - Tighten [2x] - Fastener Specifications
Transmission Mount Bracket Bolt (1) - Tighten [4x] - Fastener Specifications
- Remove the jack stand.
Floor Panel Number 2 Cross Bar Reinforcement (2) - Install
- Floor Panel Number 2 Cross Bar Reinforcement Bolt (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Intermediate Underbody Heat Shield (2) - Install
- Exhaust Heat Shield Bolt (1) - Install and tighten [6x] - Fastener Specifications
Catalytic Converter Gasket (2) - Install NEW
- With the aid of an assistant, install the exhaust system to the vehicle. (1)
- {If equipped} Electrical Connector @ Exhaust Control Valve Actuator - Connect
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install
Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Install
- Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install
Catalytic Converter Nut (1) - Install and tighten [2x] - Fastener Specifications
Floor Panel Reinforcement (2) - Install
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front End Sheet Metal Cross Brace Bolt (1) - Install and tighten [6x] - Fastener Specifications
Underbody Rear Air Deflector - Right Side (5) - Install
- Underbody Rear Air Deflector Plastic Nut (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Screw (1) - Install and tighten - Fastener Specifications
Rear Tire Front Air Deflector - Right Side (2) - Install
- Rear Tire Front Air Deflector Bolt (1) - Install and tighten [2x] - Fastener Specifications
Underbody Rear Air Deflector - Left Side (5) - Install
- Underbody Rear Air Deflector Plastic Nut (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Screw (1) - Install and tighten - Fastener Specifications
Rear Tire Front Air Deflector - Left Side (2) - Install
- Rear Tire Front Air Deflector Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Remove the support and lower the vehicle.
- Inspect the exhaust system for leaks.
- Refill the fuel tank.
- Inspect for fuel leaks.
Refer to Fastener Caution .
For proper bolt alignment, loosely install all mount bolts prior to tightening to specifications.