Axle Shaft: Service and Repair

CAUTION: If removing both righthand and lefthand driveshafts, install plugs T81P-1177B, or equivalent. Failure to do so may result in dislocating of differential side gears, requiring transaxle disassembly to align the gears. Also, driveshaft removal and installation procedures are the same for manual and automatic transaxles except for the following: due to automatic transaxle case configuration, the righthand driveshaft assembly must be removed first. Removal tool T81P-4026-A, or equivalent, is then inserted into the transaxle to remove the lefthand inner CV joint assembly. If only the lefthand driveshaft is to be removed from the vehicle, remove the righthand driveshaft assembly from the transaxle case only and secure to the vehicle's underside, then remove the lefthand driveshaft assembly. The hub nut and lower control arm to steering knuckle attaching bolt and nut must be discarded after removal and new nuts and bolts installed.

NOTE: Driveshaft assembly removal and installation procedures are the same for ATX/FLC (automatic transaxle/fluid lock-up converter) applications as for MTX (manual transaxle) applications. However, the ATX/FLC case configuration requires that the righthand driveshaft assembly be removed first. Differential rotator tool T81P-4026-A, or equivalent, should then be inserted into the transaxle to drive the lefthand inboard CV joint assembly from the transaxle. If only the lefthand driveshaft assembly is to be removed for service, remove the righthand driveshaft assembly from the transaxle only. After removal, support it with a length of wire, then drive the lefthand driveshaft assembly from the transaxle case.

NOTE: Do not begin this removal procedure unless the following new parts are known to be available: hub retainer nut, longer lower control arm to steering knuckle attaching bolt and nut and inboard CV joint stub shaft snap ring. Once removed, these components must not be reused during the assembly procedure, as their torque holding ability or retention capability is greatly diminished during removal.

1. Loosen hub nut without unstaking. Use of a chisel or similar tool to unstake nut may damage spindle threads.
2. Raise and support vehicle, then remove wheel assemblies.
3. Remove hub nut and washer. Discard hub attaching nut. It is a torque prevailing design and cannot be reused.
4. Remove bolt attaching brake hose routing clip to suspension strut.
5. Remove nut from ball joint to steering knuckle attaching bolt, then drive bolt from knuckle using a punch and a hammer. Discard bolt and nut. These are a torque prevailing design and cannot be reused.

Fig. 1 Ball Joint Separation Form Steering Knuckle:

6. Separate ball joint from steering knuckle using pry bar. Lower ball joints fit into a pocket formed in the plastic disc brake shield. The shield must be positioned away from the ball joint while removing ball joint from steering knuckle.

Fig. 2 Driveshaft Removal From Differential Housing:

7. Remove driveshaft from differential housing using a pry bar. Use caution not to damage dust deflector located between shaft and case. If an automatic transaxle driveshaft assembly cannot be removed from differential by using a pry bar, insert a large bladed screwdriver between differential pinion shaft and inboard CV joint stub shaft. Sharply tap on screwdriver handle to free driveshaft from differential. Use caution not to damage differential oil seal, joint boot or dust deflector.
8. Suspend shaft from a sturdy underbody component. Do not allow shaft to hang as outboard CV joint damage may result.

Fig. 3 Outer CV Joint Separation From Hub:

9. Separate outer CV joint from hub using puller T81P-1104C, or equivalent, and adapters T81P-1104B and T81P-1104A, or equivalents. Do not use a hammer to separate outboard CV joint stub shaft from hub, as damage to internal components may result.
10. Reverse procedure to install, noting the following:
a. Install new circlip on inboard CV joint stub shaft.
b. Align splines of inboard stub shaft with splines in differential.

Installing Shaft:

c. Push joint into differential until circlip seats in side gear.
d. Tighten new control arm to steering knuckle nut to 40-54 ft lb.
e. Tighten brake hose routing clip to strut attaching bolt to 10-11 ft lb.
f. Tighten wheel lug nuts to 80-105 ft lb.
g. Tighten new hub nut to 180-200 ft lb. During tightening, an audible click will indicate proper ratcheting function of nut. As nut tightens, ensure one of three locking tabs on nut is aligned with CV joint shaft slot. If nut is damaged or more than one locking tab is missing, replace hub attaching nut.