Output Shaft: Service and Repair

NOTE: Special tools: 999 5045, 999 5540, 999 5564, 999 5659, 999 5660

Removing Drive Shaft





Raise The Car

NOTE: Follow instructions on positioning lift arms carefully according to Towing, changing wheels and rolling road/wheel spinner test.

Remove:
- wheel
- ABS sensor. Tape sensor to track rod.

NOTE: Do not disconnect connector.

- Drive shaft nut, use a counterhold. 999 5540.





Removing Brake Components

Remove:
- counterhold
- brake caliper, hang it up by a wire to avoid stretching the brake hose
- parking brake cable mountings





Removing Suspension Components

Remove:
- track rod-wheel bearing housing screw
- track rod from wheel bearing housing
- wheel bearing housing-lower control arm nut
- screw (tap out screw with a copper mallet).





Disconnecting Bushing Lug From Wheel Bearing Housing
- Remove upper control arm/wheel bearing housing nut.
- Tap bushing lug off the stub axle.
- Use a copper mallet.





Removing Wheel Bearing Housing
- Remove upper control arm bushing nut.
- Unhook wheel bearing housing from control arm and drive shaft. Hang up bearing housing in anti-roll bar.
- Use hook 999 5045.

NOTE: Take care not to bend parking brake cable or damage its sleeve.





Removing Drive Shaft
- Remove drive shaft from final drive.
- Lever or knock in a screwdriver between CV joint housing and final drive to release the snap ring. Remove drive shaft. Take care not to damage the seal in the final drive.





Replacing Drive Shaft Seal
- Remove seal.
- Use a jimmy bar.
- Check that no seal residue is left in the final drive.





Install New Seal
- Lubricate seal with wheel bearing grease, P/N 1161241-3.
- Press in seal with drift 999 5564.
- Tap in seal until drift bottoms on its stop in final drive
- housing.





Installing Drive Shaft
- Install drive shaft in final drive.
- Take care not to damage the seal.
- Press in drive shaft firmly so that the snap ring engages in its groove. Check by carefully pulling inner CV joint.





Installing Wheel Bearing Housing
- Align wheel bearing housing with drive shaft and upper control arm bushing.
- Install a new locknut loosely.





Installing Control Arm And Track Rod
- Press lower control arm up into normal position.
- See Use tensioner 999 5659.
- Align wheel bearing housing with lower control arm bushing. Install screw with a new locknut. Hook track rod onto wheel bearing housing. Apply a few drops of locking fluid in the track rod screw.

Tighten:
- upper control arm nut to 115 Nm (84.8 ft.lb.)
- lower control arm nut to 80 Nm (59.0 ft.lb.)
- track rod screw to 80 Nm (59.0 ft.lb.)
- Remove tools.





Installing Brake Components

Install:
- brake caliper. Use new screws. Tighten to 60 Nm (44 ft.lb.)
- ABS sensor. Lubricate mounting hole first. Tighten to 10 Nm (7.4 ft.lb.)
- parking brake cable clamps
- counterhold 999 5540. Lubricate drive shaft nut
- new drive shaft nut. Tighten to 120 Nm (88.5 ft.lb.), angle-tighten to 600.
- Remove counterhold.
- Check oil level in final drive. Top up if necessary. P/N oil, 1161329-6.
- Install wheel according to Tightening wheel studs page 11.