Axle Shaft Assembly: Service and Repair
FRONT DRIVE AXLE SERVICEREMOVAL
1. Remove wheel cover, cotter pin and driveshaft nut, then loosen wheel nuts.
2. Raise and support vehicle.
3. Remove front wheel and tire assembly.
4. Drain transaxle oil.
5. Detach snap ring installed on spline of inboard joint using a large screwdriver.
6. Remove knuckle and hub assembly as described in the ``Front Suspension & Steering Section.''
7. Unfasten inboard joint from differential side gear and outboard joint from steering knuckle, then remove drive axle assembly.
Fig. 1 Exploded view of drive axle assembly:
DISASSEMBLY
Double Offset Joint
1. Secure axle assembly, Fig. 1, in a suitable soft-jawed vise.
Fig. 2 Boot band removal:
2. Remove boot band from differential side joint, Fig. 2.
Fig. 3 Circular clip removal:
3. Move boot slightly and remove circular clip, Fig. 3.
Fig. 4 Bearing removal:
4. Separate case from shaft and remove 6 balls with a suitable screwdriver, Fig. 4.
5. Turn ball guide on an angle and move it to center shaft side.
Fig. 5 Snap ring removal:
6. Remove snap ring from shaft, Fig. 5, then slide out ball guide and retainer.
7. Remove boot from shaft.
Birfield Joint
The Birfield joint must be serviced as an assembly only, however, then boot may be removed in the same manner as described for the Double Offset type joint.
Fig. 1 Exploded view of drive axle assembly:
Tripod Joint
1. Secure axle assembly, Fig. 1, in a suitable soft-jawed vise.
2. Using a screwdriver, remove boot band from differential side joint.
Fig. 6 Removing housing from shaft:
3. Make alignment marks on both housing and shaft, then remove housing from shaft, Fig. 6.
Fig. 7 Tripod removal:
4. Remove snap ring from shaft, then make alignment marks on both shaft and tripod, Fig. 7.
5. Using a suitable hammer and brass drift, remove tripod from shaft. Take care not to hit roller.
6. Remove boot from shaft, and if necessary, dynamic damper.
Fig. 8 Birfield joint inspection:
INSPECTION
1. Visually inspect all components and replace those showing signs of damage or excessive wear.
2. Check Birfield joint by bending joint approximately 40° and rotating the shaft to ensure smooth and normal rotation, Fig. 8.
Fig. 9 Circular clip installation:
Fig. 10 Circular clip alignment:
ASSEMBLY
Double Offset Joint
1. Assemble in the reverse order of disassembly, noting the following:
a. Use care to avoid damaging boot when installing boot on shaft.
b. Install and align circular clip as shown, Figs. 9 and 10.
Fig. 11 Boot band installation - Double Offset Joint:
c. To install boot band, first insert a screwdriver into end of boot, then install band as shown, Fig. 11. Ensure band end clip is securely tightened around the band and boot is not twisted.
Fig. 12 Boot band installation. Tripod Joint:
Tripod Joint
Assemble in the reverse order of disassembly, noting the following:
a. Tape spline section of shaft with tape to prevent damage to boot when installing.
b. Install tripod onto shaft with shorter spline positioned on the outer side.
c. Ensure all alignment marks align before assembling.
d. Wind boot band twice, Fig. 12, then tighten band using pliers. Finally, lock band using a suitable punch, Fig. 12.