Intermediate Shaft

Removal
1. Drain the differential oil.
2. Remove the left driveshaft.





3. Remove the three flange bolts.





4. Remove the intermediate shaft from the differential.

Disassembly

NOTE: The bearing support is made of aluminum. Be careful not to damage it when servicing.





1. Remove the set ring.
2. Remove the intermediate shaft outer seal from the bearing support.





3. Remove the external snap ring and the internal snap ring.





4. Press the intermediate shaft out of the shaft bearing sing a press as shown.





5. Press the intermediate shaft bearing out of the bearing support using the special tools and a press as shown.





6. Remove the intermediate shaft inner seal from the bearing support.

Reassembly





CAUTION:
- The bearing support is made of aluminum. Be careful not to damage it when servicing.
- Do not damage the lip on the inner and outer seals during installation.

NOTE: Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent.





1. Press the intermediate shaft inner seal into the bearing support using the special tools and a press as shown.





2. Press the intermediate shaft bearing into the bearing support using the special tool and a press as shown.





3. Seat the internal snap ring into the groove of the bearing support.





4. Press the intermediate shaft into the shaft bearing using the special tool and a press as shown.





5. Seat the external snap ring into the groove of the intermediate shaft.





6. Press the outer seal into the bearing support using the special tools and a press as shown.

NOTE: Drive in the outer seal until it is 7.0 mm (0.28 inch) from the end of the bearing support.

7. Install the new O-ring into the bearing support groove.
8. Install the new set ring into the intermediate shaft groove.

Installation





1. Insert the intermediate shaft into the differential with "LOWER" mark facing down.

NOTE: Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or carburetor cleaner, and dry with compressed air.





2. Install the three flange bolts, then tighten them.