Axle Shaft: Service and Repair

REMOVAL





1. Remove wheelcover/hub cover from wheel and tire assembly and loosen lug nuts.

CAUTION: Do not begin this removal procedure unless the following parts are available:
- A new front axle wheel hub retainer assembly.
- A new lower control arm-to-steering knuckle pinch bolt and nut.
- A new driveshaft bearing retainer circlip.
Once removed, these parts must not be reused during assembly. Their torque-holding ability or retention capability is diminished during removal.








2. After raising the vehicle on a frame contact hoist and removing the wheel and tire assembly, remove the front axle wheel hub retainer.

CAUTION: Discard the front axle wheel/hub retainer nut. It is a torque prevailing design and cannot be reused.

3. Remove stabilizer bar link top retaining nut with box end wrench while holding stud with socket.
4. Remove stabilizer bar link from front strut. Position out of way.
5. Install Front Hub Remover/Replacer 204-069 (T81P-1104-C) and Two Stud Adapter 205-237 (T86P-1104-A1), Metric Hub Remover Adapters 204-085 (T83P-1104-BH) and Front Hub Replacer 204-067 (T81P-1104-A).

Push front wheel driveshaft joint only to the point that the splines are free in the hub. Remove puller (assembled tool).

CAUTION: Never use a hammer to separate the outboard front wheel driveshaft joint stub shaft from the hub. Damage to the front wheel driveshaft joint threads and internal components may result.





6. Remove and discard lower ball joint nut. Using Ball Joint Remover Adapter 211-S200 (T96P-3010-Al), Tie Rod End Remover Adapter 211-087 (T8IP-3504-W) and Pitman Arm Puller 211-003 (T64P-3590-F), separate lower ball joint from front suspension lower arm.





7. Using Rotunda Spring Compressor 164-R3571 or equivalent, compress front coil spring until ball joint stud is free from front suspension lower arm. Pull hub and strut assembly outward, remove CV joint stub shaft from hub, rest halfshaft on frame rail.





8. Assemble CV Joint Puller T86P-3515-A1, CV Joint Puller Extension 205-243 (T86P-3514-A2) and Impact Slide Hammer 1 00-DO06 (D79P-1 00-A) or equivalent. Insert CV joint puller adapter behind inboard CV joint housing.





9. Use impact slide hammer to release circlip.





10. Remove halfshaft assembly and tools from vehicle.

INSTALLATION

1. Install a new circlip on the inboard CV joint housing.

CAUTION: DO NOT reuse circlip. A new circlip must be installed each time the inboard CV joint housing is installed into the transaxle differential. Clean seal journal before installing. Polish with fine emery paper if required.

NOTE: To properly install the circlip, start one end in the groove and work the circlip over the inboard CV joint housing end and into the groove. This will avoid over-expanding the circlip.





2. Carefully align splines of inboard CV joint housing with the splines in the differential side gear. Exerting some force, push inboard CV joint into differential side gear until the circlip is felt to seat in the differential side gear.

NOTE: A non-metallic mallet may be used to aid in seating the circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard CV joint stub shaft.





Use care to prevent damage to the inboard CV joint stub shaft pilot bearing housing seal.





3. Carefully align splines of front wheel driveshaft joint with splines in wheel hub and push the shaft into the wheel hub as far as possible.





4. Install a new front axle wheel hub retainer. Manually thread the front axle wheel hub retainer onto the front wheel driveshaft joint threads as far as possible.

CAUTION: A new front axle wheel hub retainer must be installed.





5. Release Rotunda Spring Compressor 164-R3571 or equivalent while guiding lower ball joint into front suspension lower arm. Install new lower ball joint nut. Tighten to 68-92 Nm (51-67 ft lb).
6. Install stabilizer bar link to front shock absorber and install a new nut. Tighten to 77-103 Nm (57-75 ft lb).





7. With steel rod inserted in front disc brake rotor, tighten front axle wheel hub retainer to 245-270 Nm (180-200 ft lb) as shown.

CAUTION: Do not use power tool to tighten front axle wheel hub retainer. Use torque wrench.

8. Install tire and wheel. Tighten lug nuts to 115-142 Nm (85-104 ft lb).
9. Lower vehicle.
10. Fill transaxle to proper level with specified fluid.
11. Pump brake pedal prior to moving vehicle to position brake linings.