Alero, Grand Am 1999-2005

Removal & Installation

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Intermediate Shaft





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Fig. Intermediate shaft components

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Install an engine support fixture.
  4.  
  5. Remove or disconnect the following:

    Right side wheel
     
    Sway bar link kit
     
    Lower ball joint from the steering knuckle
     
    Halfshaft from the intermediate shaft
     
    Intermediate shaft support bracket-to-engine bolts
     
    Intermediate shaft from the transaxle
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    If necessary, tighten the nut up to 60 degrees ( 1 / 6 ) turn additional rotation to align the cotter pins. NEVER loosen the nut to make the holes align.



    Intermediate shaft into the transaxle. Torque the intermediate shaft support bracket-to-engine bolts to 49 ft. lbs. (66 Nm). Coat the splines of the intermediate shaft with chassis grease.
     
    Halfshaft to the intermediate shaft
     
    Lower ball joint to the steering knuckle. Torque the castle nut to 44 ft. lbs. (60 Nm).
     



    New cotter pin
     
    Sway bar link kit. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Wheel. Torque the nuts to 100 ft. lbs. (140 Nm).
     

  2.  
  3. Remove the engine support fixture.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Check the transaxle fluid level and top off as necessary.
  8.  

Left & Right



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Wheel
     
    Hub nut and washer
     
    Lower ball joint from the steering knuckle
     
    Anti-lock Brake System (ABS) electrical connector
     
    Sway bar link kit
     

  4.  
  5. Press the halfshaft from the hub/bearing assembly.
  6.  
  7. Pull the halfshaft from the transaxle using a slide hammer and axle removal tool.
  8.  

To install:

  1. Install or connect the following:
    NOTE
    Verify the joint is seated properly by grasping the inboard joint and pulling on it firmly.


    WARNING
    DO NOT pull on the halfshaft or damage to the inner joint may result.


    NOTE
    If necessary, tighten the nut up to 60 degree ( 1 / 6 ) turn additional rotation to align the cotter pins. NEVER loosen the nut to make the holes align.



    Halfshaft into the transaxle or intermediate shaft using a brass drift positioned in the inboard joint groove and tap the joint in until it is seated
     



    Halfshaft into the hub assembly
     
    Lower ball joint to the steering knuckle. Torque the nut to 44 ft. lbs. (60 Nm).
     



    New cotter pin
     
    Washer and hub nut. Torque the hub nut to 284 ft. lbs. (385 Nm) on nuts that are colored black, or 183 ft. lbs. (235 Nm) on nuts that are colored gray.
     
    Sway bar link kit. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Wheel. Torque the nuts to 100 ft. lbs. (140 Nm).
     
    Negative battery cable
     

  2.  
  3. Check the transaxle fluid level and top off as necessary.
  4.  

 
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