Drive Axles, Bearings and Joints: Service and Repair
- TOOLS REQUIRED
- J-43628 Frame Alignment Fixture
- SA9105E Engine Support Fixture
- J-43405 Engine Support Fixture Adapter
- SA9140E Torque Angle Gauge
REMOVAL
1. Install engine support fixture. (L61 engine)
2. Install engine support fixture. (L81 engine)
3. On vehicles equipped with L81 engines, remove rear exhaust manifold pipe heat shield.
4. Remove rear transaxle mount through bolt, and transaxle mount-to-frame bolt.
5. Fasten radiator to upper radiator support.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
6. Raise vehicle on hoist.
7. Remove front wheel and tire assemblies.
8. Remove right front lower splash shield.
9. Remove left front wheel liner push pin from frame.
10. Disconnect rear O2 sensor connection, and remove harness from frame at attachment points.
11. Remove exhaust manifold pipe on L81 engines, and on L61 engines with manual transaxle. (L81 shown)
12. Remove front transaxle mount through bolt.
13. Remove remaining rear transaxle mount-to-frame bolts.
14. Remove A/C line to frame attachment clip at front of vehicle.
15. Remove steering gear-to-frame bolts. Discard bolts and nuts.
16. On vehicles equipped with L61 engines and automatic transaxle, remove steering gear heat shield.
17. Using mechanics wire, secure the steering gear assembly to body of vehicle.
18. Remove stabilizer bar links from strut.
NOTICE: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.
19. Remove the lower ball stud bolt and separate the ball stud from the steering knuckle assembly.
20. Remove the suspension support assemblies.
21. Remove suspension support cage nuts from the body. Discard cage nuts and support bolts, as new nuts and bolts must be used for assembly.
22. Using powertrain lifting table and the frame alignment tool J-43628, support frame assembly.
23. Remove the remaining frame-to-body attachment fasteners.
24. Carefully lower frame assembly from vehicle.
25. Remove frame assembly cage nuts from body. Discard cage nuts and frame bolts as new nuts and bolts must he used for assembly.
DISASSEMBLY
- TOOLS REQUIRED
- KM-671 Bushing Remover/Installer
- KM-906-B Bushing Remover/Installer
- KM-907 Bushing Remover/Installer
1. Remove stabilizer clamp-to-frame bolts.
2. Remove stabilizer bar and clamps.
3. Remove control arm-to-frame assembly bolts and discard bolts.
4. Remove control arm from frame.
5. Using tools KM-671, KM-907-11 (3), KM-907-12 (2) and KM-907-30 (1), press out all damping bushings.
ASSEMBLY
1. Install all damping bushings using tool KM-671 along with KM-907-13 (1) and KM-907-14 (2).
2. Install the stabilizer bar to the frame assembly
Torque: 20 Nm (15 ft. lbs.)
IMPORTANT: Use new torque retention of old bolts may not be sufficient.
3. Install control arms to frame assembly using new bolts.
Torque: 90 Nm (66 ft. lbs.) + 75 - 90°
INSTALLATION
IMPORTANT: Be sure the frame alignment tool fully engages in all gauge holes.
1. Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
2. Raise frame assembly to body.
IMPORTANT: Do not tighten fasteners at this time.
3. Install new frame-to-body bolts.
4. Install new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
5. Install suspension supports using new bolts and tighten all frame bolts.
Torque: 90 Nm (60 ft. lbs.) + 45 - 60°
6. Install lower control arm ball stud into steering knuckle.
Torque: 100 Nm (75 ft. lbs.)
7. Install steering gear-to-frame using new bolts and nuts.
Torque: 45 Nm (35 ft. lbs.) + 45 - 60°
8. Vehicles equipped with an L61 engine and automatic transaxle, install steering gear heat shield.
Torque: 4 Nm (35 inch lbs.)
9. Install stabilizer bar link-to-strut assembly.
Torque: 65 Nm (50 ft. lbs.)
10. Install two rear transaxle mount to frame bolts.
Torque: 60 Nm (44 ft. lbs.)
11. Install front transaxle mount through bolt.
Torque: 55 Nm (41 ft. lbs.)
12. Install exhaust manifold pipe on L81 engines and on L61 engines with manual transaxles. (L81 shown)
13. Tighten exhaust manifold pipe to exhaust manifold.
Torque: 30 Nm (22 ft. lbs.)
14. Tighten exhaust manifold pipe to exhaust pipe.
Torque: 20 Nm (15 ft. lbs.)
15. Reattach A/C line clip to front of frame assembly.
16. Install right front lower splash shield.
Torque: 5 Nm (44 inch lbs.)
17. Install left front wheel liner push pin to frame.
18. Connect O2 sensor electrical connector and reattach harness to frame.
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.
19. Install wheel and tire assemblies onto hub.
20. Install wheel bolts and tighten in a crisscross pattern. Repeat tightening to make sure torque is correct.
Torque: 125 Nm (92 ft. lbs.)
21. Lower vehicle.
22. Install remaining rear transaxle mount to frame bolt.
Torque: 60 Nm (44 ft. lbs.)
23. Install rear transaxle mount through bolt.
Torque: 90 Nm (66 ft. lbs.)
24. Remove engine support fixture.
25. On vehicles equipped with L81 engines, install exhaust manifold pipe heat shield.
Torque: 8 Nm (71 inch lbs.)
26. Perform vehicle alignment. (Refer to "Alignment" procedure.)