Axle Shaft: Service and Repair

CAUTION: When removing driveshafts, install differential plugs tool No. T87C-7025-C, or equivalent. Failure to do so may result in fluid leakage and dislocation of differential side gears, necessitating transaxle disassembly to align the gears again. Should the gears become misaligned, the differential will have to be removed from the transaxle for alignment.

NOTE: Do not begin this procedure unless a new hub retainer and a new inboard driveshaft bearing retainer circlip are available. Once removed, these components must not be reused during assembly/installation. Their torque holding ability or retention capability is diminished during removal.

REMOVAL
1. Raise and support front of vehicle, then remove wheel and tire assembly.
2. Remove underbody covers, then remove stabilizer bar link from control arm.

Fig. 1 Axle Nut Unstaking:

3. Using a chisel, raise staked portion of axle nut, then with brakes applied, loosen but do not remove nut.
4. Remove clamp bolt attaching lower control arm ball joint to steering knuckle.
5. Pry downward on lower control arm to separate ball joint from steering knuckle.

Fig. 2 Driveshaft Separation. Manual Transaxle:

Fig. 3 Pry Bar Insertion For Driveshaft Separation:

6. On models with manual transaxle, pull outward on steering knuckle and hub assembly to separate driveshaft from differential side gear. Use only enough force to loosen the driveshaft. In some cases, it may be necessary to position a pry bar between driveshaft and transaxle and lightly tap end of bar to loosen driveshaft from differential side gear. When using a pry bar, use care not to damage transaxle case, oil seal or CV joint or boot. Do not pull driveshaft completely out of transaxle, as damage to oil seal may result.

Fig. 3 Pry Bar Insertion For Driveshaft Separation:

7. On models with automatic transaxle, position pry bar between transaxle case and driveshaft, then lightly tap end of bar to loosen driveshaft from differential side gear. Use care not damage transaxle case, oil seal or CV joint or boot.

Fig. 4 Driveshaft Separation From Hub & Steering Knuckle:

8. Remove axle nut and washer, then pull driveshaft from hub and steering knuckle assembly. If binding is encountered, use puller D80L-1002-L, or equivalent, to separate driveshaft from hub and knuckle assembly.
9. Support driveshaft and carefully slide from transaxle. Use care not to damage transaxle case oil seal when removing driveshaft.
10. Cap transaxle driveshaft openings.

INSTALLATION

Fig. 5 Circlip Position On Driveshaft Spline:

1. Position replacement circlip driveshaft groove at transaxle end. To prevent over expanding, position one end of circlip into groove then work other end over shaft and into groove. When installed, gap in circlip should be at top of driveshaft splines.

Installing Shaft:

2. Lightly lubricate driveshaft splines. With proper lubricant applied, position driveshaft splines to differential side splines.
3. Push driveshaft splines into differential until circlip snaps into differential side gear groove.
4. Position driveshaft through hub and steering knuckle and loosely install replacement axle nut and washer.
5. Position lower control arm ball joint to steering knuckle, then install and tighten clamp bolt to 32-42 ft lb.
6. Install stabilizer bar link to lower control arm. Tighten nut until 0.43 inch of bolt thread extends beyond nut.
7. Install underbody covers.

Fig. 7 Axle Nut Staking:

8. Tighten axle nut to 116-174 ft lb, then stake nut using a chisel, Fig. 7. If nut is damaged during staking, it must be replaced.
9. Install wheel and tire assembly, then lower vehicle.