I did my 5.38 front install while everyone else was in Moab!
Talking about a 91 Trooper here, so yours may vary.
Take off the brake caliper and tie it up out of the way. The front stabilizer bar will have to come off(no biggie). The tie-rod end does not have to come off. The hub does not have to come off. I removed the top ball joint by just taking out the four bolts(propping it up with a big wrench) and then letting the lower arm swing gently down, using my legs as a dropping bench(I had already flipped the ball joints). Took the CV joint inner boot loose, and pulled the circlip out of the inner can, then gently worked the CV shaft around, turning the wheel hub, until the ball collector thinging just came out. It will come out, along with all the balls, but you need to clean them up anyway prior to re-installing them. Learned this technique from Jerry Lemond!
Bought all my parts from Jerry as well. Had Fort Worth Gear & Axle install the 5.38 set AND the front ARB locker. Their bill was $200.00. Don't let the gear changers buy the parts! They will buy them from Isuzu dealers and add a nice(for them)markup. Buy the stuff from Jerry. If you do, you will also enjoy a very nice learning experience. I bought all seals, crush sleeve, carrier bearings, etc from him. Saved a lot of money.
Goes back together easily the same way. Look out, that front axle housing is very heavy and you will need to wiggle the lower a-frame a little to get the clearance necessary to drop it out as it will still have the inner cans attached.
Have the t-case at FW B&T now for the Teralow install. Should have it back this week and will be up and running shortly!!!!!!!
Bob
'91 Trooper 3.4 V6 ARBs F&R, 33" BFG, 3.07 Teralows, 5.38 F&R, 4" lift, boulder bars, roof rack, torsion bars, Matt's tie-rod ends, manual hubs, heavy springs, homemade front and rear bumpers,rock sliderz, etc. 2000 Trooper
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