Removal and Installation

CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage.

REMOVAL

CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 203 Nm (150 ft. lbs.). This will ensure that the hub bearing cannot loosen.

Fig. 2:

1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle.

Fig. 3:

2. Loosen (but do not remove) stub axle-to-hub/ bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut.
3. Raise vehicle on jack stands or centered on a frame contact-type hoist.
4. Remove front tire and wheel assembly from the hub.

Fig. 4:

5. Remove front disc brake caliper assembly to steering knuckle bolts.
6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle.

Fig. 5:

7. Support brake caliper/adapter assembly using a wire hook, not by the brake flex hose.
8. Remove braking disc from front hub.
9. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure: Hold tie rod end stud with a 11/32 socket while loosening and removing nut.

Fig. 6:

10 Remove the tie rod end stud from steering knuckle arm using Special Tool MB-991113.

Fig. 7:

11 Remove nut and bolt retaining ball joint stud into steering knuckle.

NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.

Fig. 8:

12 Separate ball joint stud from steering knuckle by prying down on lower control arm.

NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported.

13 Remove the hub and bearing to stub axle retaining nut.

Fig. 9:

14 Install Puller, Special Tool 6790 on hub and bearing assembly, using wheel lug nuts to secure it in place.

Fig. 10:

15 Install a wheel lug nut on wheel stud to protect the threads on the stud. Install a flat blade pry tool to keep hub from turning. Using Puller, force the outer stub axle from the hub and bearing assembly.

Fig. 11:

16 Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft, assembly.
17 Support outer end of the driveshaft assembly.

NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer.

Fig. 12:

Fig. 13:

18 Remove the inner tripod joints from the side gears of the transaxle using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear.

Fig. 14:

19 Hold inner tripod joint and interconnecting shaft of driveshaft, assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. When tripod joint is removed from transaxle, some fluid will leak out.

CAUTION: The driveshaft, when Installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 203 Nm (150 ft. lbs.). This will ensure that the hub bearing cannot loosen.

INSTALLATION
1. 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.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand.
3. Carefully align tripod joint with transaxle side gears. Then grasp driveshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.

Fig. 15:

4. Clean all debris and moisture out of steering knuckle.

Fig. 16:

5. Ensure that front of outer C/V joint, which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle.

Fig. 17:

6. Slide driveshaft back into front hub. Install steering knuckle onto the ball joint stud.

Fig. 18:

7. Install a NEW steering knuckle to ball joint stud bolt and nut. Tighten the nut and bolt to 95 Nm (70 ft. lbs.).
8. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Then, using a crowfoot and 11/32 socket, tighten tie rod end nut to 61 Nm (45 ft. lbs.).
9. Install braking disc back on hub and bearing assembly.
10 Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle.

Fig. 19:

11 Install caliper assembly to steering knuckle bolts. Tighten to 31 Nm (23 ft. lbs.).
12 Clean all foreign matter from threads of outer C/V joint stub axle. Install washer and hub nut onto the threads of the stub axle and tighten nut.

Fig. 20:

13 Install spring washer, nut lock, and cotter pin on outer C/V joint stub axle.
14 With vehicle brakes applied to keep axle shaft from turning, tighten hub nut to 203 Nm (150 ft. lbs.).
15 Install front wheel and tire assembly. Install front wheel lug nuts and tighten to 135 Nm (100 ft. lbs.).
16 Check for correct fluid level in transaxle assembly. Refer to procedure for the type of transaxle being checked.
17 Lower vehicle.