Seals and Gaskets: Service and Repair

AXLE SEALS

- TOOLS REQUIRED
- J44015 Steering Linkage Installer
- SA91100C Tie Rod Separator
- SA91112T Axle Seal Protector Tool
- SA9113T Axle Seal Installer
- SA9133T Axle Seal Remover

REMOVAL

CAUTION: TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE AT THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. THIS WILL REDUCE THE POSSIBILITY OF THE VEHICLE FALLING OFF OF THE HOIST.

1. Raise vehicle.





2. Remove wheel and tire assembly on side that requires axle seal removal.





3. Drain transaxle lubricant by removing transaxle drain plug (1).





4. Remove tie rod end nut and discard.

NOTICE: Do not attempt to separate the joint using a wedge-type tool because the seal may be damaged.





5. Using Tie Rod Separator SA91100C (or equivalent), separate tie rod end from steering knuckle.





6. Remove lower control arm to steering knuckle nut and bolt.

NOTICE: Be careful not to allow steering knuckle to contact ball stud seal. Contact may cause the seal to tear, requiring ball stud replacement.

IMPORTANT: Place a cloth over the ball stud boot protecting it from damage caused by contact with the steering knuckle.

7. Separate lower control arm from steering knuckle.

NOTICE: To prevent damage to CV Joint boots, be careful not to allow them to contact other parts during the removal/installation process. Also, never pull on the shaft assembly.





8. Using a pry bar, remove drive axle from transaxle.
9. Leave axle in steering knuckle, and tie drive axle out of the way.





10. Remove axle seal using Axle Seal Remover SA9133T.
10.1. Remove dust cover by prying out with a screwdriver.
10.2. Remove seal by threading puller through steel seal body as close to the outside diameter as possible.

INSTALLATION





1. Clean seal bore in housing.
2. Apply a light bead of Loctite 515(r) Gasket Eliminator Sealant (P/N 21005993) or equivalent on the diameter of the seal that presses into case bore.

NOTICE: Prior to using seal installer SA9113T, inspect tool for any nicks or burrs that may damage seal lip.

3. Install axle seal using Axle Seal Installer SA91 13T. Place seal on tool and insert into transaxle. Make sure to keep seal lined up with bore during installation. (Right side shown, left side similar.)

NOTICE: Use caution not to damage seal while installing axle into transaxle.





4. Install Axle Seal Protector Tool SA91112T inside seal.
5. Install axle into transaxle.
6. After shaft splines clear the seal but before snapping axle into place, remove seal protector tool.
7. Push axle all the way into the transaxle.

NOTICE: Take care not to damage rubber boot when installing ball joint to knuckle.





8. Insert lower control arm ball stud into steering knuckle.
9. Install lower control arm ball stud retaining bolt and nut.
Torque: Lower Control Arm Ball Stud Bolt and Nut-to-Steering Knuckle: 100 Nm (75 ft. lbs.)

IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.





10. Install tie rod end into steering knuckle.
11. Using Steering Linkage Installer J44015, seat tie rod end into steering knuckle.
Torque: Linkage Installer J44015-to-Seat Tie Rod Ends: 45 Nm (35 ft. lbs.)

NOTICE: Use a new nut. Torque retention of old nut may not be sufficient.

12. Remove linkage installer and install a new tie rod end nut.
Torque:
Tie Rod End-to-Steering Knuckle: 60 Nm (45 ft. lbs.)





13. Clean and apply thread sealant (P/N 21485278) to the transaxle drain plug (1) and install.
Torque:
Transaxle Drain Plug: 50 Nm (37 ft. lbs.)
14. Remove the transaxle level plug (2) and, using a funnel with a flexible spout or a quart bottle hand pump, add manual transaxle lubricant (P/N 21018899) until fluid begins to flow out of the level plug opening.
15. Clean and apply thread sealant (P/N 21485278) to transaxle level plug and install.
Torque:
Transaxle Level Plug: 50 Nm (37 ft. lbs.)

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.





16. Position wheel onto hub.
17. Install wheel bolts and tighten in a star pattern.
17.1. Hand tighten all five wheel bolts.
17.2. Use a torque wrench to tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
17.3. Use a torque wrench to final tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
18. Lower vehicle from hoist.