Drive Axles, Bearings and Joints: Service and Repair
DRIVE AXLE- TOOLS REQUIRED
- J44015 Steering Linkage Installer
- SA91100C Tie Rod Separator
- SA91112T Axle Seal Protector
- SA9161C Axle Boot Clamp Installer
- SA9161C Axle Clamp Installer
- SA9198C C/V Joint Snap Ring Pliers
- SA9203C Axle Boot Clamp Installer
REMOVAL
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
1. With vehicle on the ground, depress brake pedal and remove cotter and drive axle nut. Discard nut and cotter.
2. Raise vehicle on hoist.
3. Remove wheel and tire assembly corresponding to the drive axle being removed.
4. Remove tie rod end torque prevailing nut, discard nut.
NOTICE: Do not attempt to separate joint using a wedge-type tool because 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 rip, requiring ball stud replacement.
NOTICE: Place a cloth over the ball stud boot, protecting it from damage caused by contact with steering knuckle.
7. Separate lower control arm from steering knuckle.
NOTICE: To prevent damage to the 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.
IMPORTANT: If difficulty is encountered in separating axle from hub tap on end of drive axle, using a block of wood and a hammer. Do not hammer directly on end of axle.
8. While pulling knuckle/strut assembly away from vehicle pull outer end of drive axle out of wheel hub.
9. Support or suspend drive axle assembly.
NOTICE: When removing the right side drive axle on vehicles equipped with automatic transaxles, the stub shaft may come out of the transaxle with the drive axle. When this occurs inspect the seal for damage and replace if necessary. If seal is damaged, refer to Right Side Axle Seal.
IMPORTANT: Before removing drive axle, place an approved container under the transaxle to catch any fluid spillage
10. Using a pry bar, remove drive axle from transaxle.
11. Remove shaft retaining ring from end of drive axle or stub shaft and discard (stub shaft shown).
DISASSEMBLY
NOTICE: Use soft metal or wood in between vice jaws to protect the shaft.
1. Clamp the drive axle shaft in a vice.
2. Remove outer CV joint and joint boot.
2.1. Use a hammer and chisel or a flat blade screwdriver to disengage outer band from inner band at retainer peg on both large and small boot clamps and discard clamps.
2.2. Separate joint boot from CV joint race at large diameter and slide boot away from joint along axle shaft.
2.3. Wipe excess grease from face of CV inner race.
2.4. Using a rubber mallet, or block of wood and hammer, carefully tap on CV joint to remove from axle.
2.5. Remove boot from axle shaft.
3. Disassemble CV joint.
3.1. Using a brass drift, gently tap on cage until tilted enough to remove first ball.
3.2. Remove remaining balls in similar manner.
3.3. With all balls removed, pivot cage and inner race at 90 degrees to center line of outer race with cage windows aligned with lands of outer race, lift out cage and inner race.
3.4. Rotate inner race up and out of cage.
3.5. Thoroughly degrease all CV joint parts and allow to dry prior to assembly.
4. Assemble CV joint.
4.1. Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
4.2. Put a light coat of recommended grease on inner and outer race grooves.
4.3. Insert and rotate inner race into cage.
4.4. Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
4.5. Install balls using a brass drift to gently rotate and position cage and inner race.
4.6. Pack assembled joint with grease provided in service kit. (The amount of grease supplied with service kits has been pre-measured for each application.)
5. Remove tri-pot joint and joint boot.
5.1. Cut eared boot retaining clamp on tri-pot boot with side cutters and discard.
5.2. Remove earless clamp, using a small-blade screwdriver and discard.
5.3. Separate boot from tri-pot housing at large diameter and slide boot away from joint along axle shaft.
5.4. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
5.5. Remove tri-pot housing from the spider and shaft.
NOTICE: Handle the tri-pot spider assembly with care. Tripot-pot balls and needle rollers may separate from spider trunnions.
5.6. Remove spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
5.7. Remove boot from axle shaft.
5.8. Thoroughly degrease the housing and allow to dry prior to assembly.
ASSEMBLY
1. Install tri-pot joint and boot.
1.1. Inspect tri-pot joint components for unusual wear, cracks, and other damage, and replace any needed components.
1.2. Clean the shaft. If rust is present in the boot mounting area (grooves), wire brush this area.
1.3. Install small boot retaining clamp on neck of boot. Do not crimp.
1.4. Slide boot onto shaft and locate neck of boot in proper position in boot groove on axle shaft.
1.5. Crimp boot retaining clamp with Axle Boot Clamp Installer SA9203C (or equivalent) as shown.
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
1.6. Measure clamp end gap, and repeat step 1.5. if necessary. Dimension should not exceed 2.15 mm (0.85 inch).
1.7. Slide tri-pot spider assembly past spider retaining ring groove until seated against shoulder.
NOTICE: Be sure that counterbored surface of tri-pot spider faces end of shaft after installation.
1.8. Install spider retaining ring in groove of axle shaft with C/V Joint Snap Ring Pliers SA9198C (or equivalent).
1.9. Place approximately half of the grease (provided in kit) inside boot and use the remainder to repack tri-pot housing.
1.10. Install convoluted retainer (supplied with service kit) over boot.
NOTICE: Joint must be assembled with convoluted retainer in position. Boot damage will result if joint is not assembled correctly.
1.11. Position boot retaining clamp around large diameter of boot.
1.12. Slide tri-pot housing over tri-pot spider assembly on shaft.
1.13. Slide large diameter of boot over outside of tri-pot housing and locate lip of boot in housing groove.
NOTICE: Boot must not be dimpled, stretched, or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and housing to equalize pressure. Shape boot properly by hand and remove tool.
1.14. Place large boot retaining clamp around boot and close with Axle Boot Clamp Installer SA9161C (or equivalent).
2. Install outer CV joint and boot.
2.1. Install small retaining clamp on neck of new boot. Do not crimp.
2.2. Slide boot onto axle shaft and locate neck of boot in proper position in boot groove on axle shaft.
2.3. Crimp boot retaining clamp with Axle Boot Clamp Installer SA9203C (or equivalent).
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
2.4. Measure clamp end gap dimension and repeat step 2.3 if necessary. Dimension should not exceed 2.15 mm (0.85in.).
2.5. Place approximately half of grease (provided in kit) inside boot and repack CV with remaining grease.
2.6. Position large boot retaining clamp around boot.
NOTICE: Be sure that retaining ring side of inner race faces axle shaft prior to installation.
2.7. Push CV joint onto axle shaft until retaining ring is seated in groove on axle shaft.
2.8. Slide large diameter of boot over outside of CV joint race and locate lip of boot in housing groove.
NOTICE: Boot must not be dimpled, stretched, or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and housing to equalize pressure. Shape boot properly by hand and remove tool.
2.9. Crimp retaining clamp with Axle Clamp Installer SA9161C (or equivalent).
IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.
2.10. Measure clamp end gap dimension and repeat Substep 2.9 if necessary. Dimension should not exceed 2.6 mm (0.102 inch)
INSTALLATION
1. Install new axle or stub shaft retaining ring.
NOTICE: When inserting drive axle into transaxle, be careful not to contact oil seal with drive axle splices. The spline can damage the oil seal.
IMPORTANT: On vehicles equipped with automatic transaxles, apply output shaft lubricant P/N 7847638 to the splines of the output shaft.
2. Install Axle Seal Protector SA91112T (or equivalent) on vehicles with manual transaxles.
3. Insert drive axle into transaxle.
4. After drive axle splines have safely passed transaxle oil seal, remove seal protector and fully seat drive axle into transaxle.
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 axle assembly.
NOTICE: Use a new nut. Torque retention of old nut may not be sufficient.
IMPORTANT: Do not tighten fastener at this time.
5. Insert outer end of drive axle into the wheel hub. Install drive axle to hub washer and new nut.
NOTICE: Be careful not to allow steering knuckle to contact the ball stud seal. Contact may cause the seal to rip.
NOTICE: Use a new nut & bolt. Torque retention of old fasteners may not be sufficient.
6. Install lower control arm ball stud into steering knuckle. Hold the bolt stationary and tighten the nut.
- Lower Control Arm-to-Steering Knuckle: 100 Nm (75 ft. lbs.)
IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.
7. Install tie rod end into steering knuckle.
8. Using Steering Linkage Installer J44015 (or equivalent) seat the tie rod end into knuckle.
- Tie Rod End Linkage Installer: 45 Nm (33 ft. lbs.)
NOTICE: Use a new nut. Torque retention of old nut may not be sufficient.
NOTICE: Hold ball stud from turning when installing nut. The boot can become torn and damaged if the ball stud turns.
9. Inspect boot for damage and replace part if damaged.
10. Remove linkage installer and install new tie rod end nut.
- Tie Rod End-to-Steering Knuckle Nut: 60 Nm (44 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.
11. Install wheel and tire assemblies onto hub.
12. Install wheel bolts and tighten in a crisscross pattern.
12.1. Hand tighten all five wheel bolts.
12.2. Use a torque wrench to tighten wheel bolts using a crisscross pattern.
- Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
12.3. Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
- Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
13. Lower vehicle from hoist
14. Fasten the axle shaft to hub nut in the following sequence.
- Axle Shaft-to-Hub (Initial Torque): 100 - 160 Nm (74 - 118 ft. lbs.) then release nut until it is free to turn by hand
- Axle Shaft-to-Hub (Final Torque): 20 Nm (15 ft. lbs.) + 90°
If required, continue turning nut until a hole for the cotter pin is aligned properly.
15. Install cotter pin.