Front Half Shaft
INSTALLATION
1. Install the intermediate shaft into the transaxle.
2. Install the bolts (2) holding the mid-shaft bearing to the block plate and tighten to 30 Nm (22 ft. lbs.).
NOTE: The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are pulled past the retention feature the joint will "lock-up" and no longer function properly. The entire halfshaft assembly must be replaced if this occurs.
NOTE: Some halfshafts use a tuned rubber damper weight. When replacing a halfshaft assembly, be sure the replacement halfshaft has the same damper weight as the original.
3. If a 2.0L gas engine with a T355 manual transmission install the one piece right halfshaft (1) into the transmission Test that snap-ring is fully engaged by attempting to remove tripod joint by hand. If snap-ring is fully engaged, tripod joint will not be removable by hand..
4. If equipted, Install the intermediate shaft into the transaxle.
5. Install the three bolts (1) holding the mid-shaft bearing (2) to the block, tighten 10 mm bolts to 38 Nm (28 ft. lbs.) and if equipped 8 mm bolts to 23 Nm (17 ft. lbs.).
6. Install the heat shield and bolts, tighten to 6 Nm (40 in. lbs.) (if equipped).
7. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
8. Holding half shaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand or onto the intermediate drive shaft. Be sure to engage splines prior to applying force.
9. Forcefully push the tripod joint onto intermediate shaft, until snap-ring is engaged. Test that snap-ring is fully engaged by attempting to remove tripod joint by hand. If snap-ring is fully engaged, tripod joint will not be removable by hand.
10. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle.
11. Ensure that front of outer CV joint (1) which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly.
12. Slide half shaft back into front hub and bearing assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle.
CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.
13. Install steering knuckle in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both bolts to 88 Nm (65 ft. lbs.) plus an additional 1/4 turn.
14. Install braking disc on hub and bearing assembly.
15. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment.
16. Install disc brake caliper adapter to steering knuckle attaching bolts. Tighten the disc brake caliper adapter attaching bolts to 169 Nm (125 ft. lbs.).
17. Clean all foreign matter from the threads of the outer CV joint. Install the half shaft to hub/bearing assembly nut on half shaft and securely tighten nut.
18. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued (1) to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
19. Lower vehicle.
20. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 160 Nm (118 ft. lbs.).
21. Check for correct fluid level in transaxle assembly. Fluid Level and Condition Check - 40/41TE