Aura, Outlook 2007

Halfshafts

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CV-Joints



Overhaul
Inner Joint

NOTE
Do not cut through the wheel drive shaft inboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

  1. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
  2.  
  3. Remove the large seal retaining clamp from the tripot joint with side cutters. Discard the large seal retaining clamp.
  4.  
  5. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter.
  6.  
  7. Slide the seal away from the joint along the halfshaft bar.
  8.  
  9. Remove the housing from the tripot joint spider and the halfshaft bar.
  10.  
  11. Spread the spacer ring using snapring pliers.

    Click image to see an enlarged view

    Fig. Inner joint components (1) Spacer ring (2) Spider assembly (3) Spacer ring (4) Tripot boot

  12.  
  13. Remove the spacer ring, spider assembly, spacer ring, if equipped and tripot boot. Discard the boot and rings.
  14.  
  15. Clean the halfshaft bar. Use a wire brush in order to remove any rust in the boot mounting area (grooves).
  16.  
  17. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit.
  18.  

To install:


NOTE
Place a towel in the vise before inserting the halfshaft.

  1. Mount the halfshaft into a vise.
  2.  
  3. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar.
  4.  
  5. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar.

    Click image to see an enlarged view

    Fig. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar



    Click image to see an enlarged view

    Fig. Crimp the eared clamp using Drive Axle Seal Clamp Pliers such as J 35910 , a torque wrench, and a breaker bar-Aura



    Click image to see an enlarged view

    Fig. Crimp the eared clamp using Drive Axle Seal Clamp Pliers such as J 35910 , a torque wrench, and a breaker bar-Outlook

  6.  
  7. Crimp the eared clamp using Drive Axle Seal Clamp Pliers such as J 35910 , a torque wrench, and a breaker bar.
  8.  
  9. If equipped, install the spacer ring into the groove of the halfshaft bar.
  10.  
  11. Slide the tripot joint spider assembly as far as it will go on the halfshaft bar.
  12.  
  13. Install the spacer ring into the groove of the halfshaft bar.
  14.  
  15. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing.
    NOTE
    Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

  16.  
  17. Install the trilobal tripot bushing (3) to housing (1).
  18.  
  19. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal.
  20.  
  21. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.

    Click image to see an enlarged view

    Fig. Install the trilobal tripot bushing (3) to housing (1), position the larger new seal retaining clamp (2) on the halfshaft inboard seal and slide the housing (1) over the tripot joint spider assembly on the halfshaft bar

  22.  
  23. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
  24.  
  25. Position the joint assembly at the proper vehicle dimension, a = 4 in. (106mm).
  26.  
  27. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool.

    Click image to see an enlarged view

    Fig. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 0.012 in. (2.6mm) is reached-Aura



    Click image to see an enlarged view

    Fig. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 5/6in. (1.9mm) is reached-Outlook

  28.  
  29. Align the following items while latching:
    1. The halfshaft inboard seal.
    2.  
    3. The tripot housing.
    4.  
    5. The large seal retaining clamp. 
    6.  

  30.  
  31. Crimp the seal retaining clamp using Drive Axle Seal Clamp Pliers such as J 35910 to 130 ft. lbs. (176 Nm). Add the breaker bar and the torque wrench to the pliers necessary.
  32.  
  33. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 0.012 in. (2.6mm) is reached on Aura models, or 5 / 6 in. (1.9mm) is reached on Outlook models.
  34.  
  35. Fully stroke the joint several times to disperse the grease
  36.  

Outer Joint
  1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp.
    NOTE
    Do not cut through the wheel drive shaft inboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint.

  2.  
  3. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp.
  4.  
  5. Separate the halfshaft outboard seal from CV joint outer race at large diameter.
  6.  
  7. Slide the seal away from joint along halfshaft bar.
  8.  
  9. Wipe the grease from the face of the CV joint inner race.
  10.  
  11. Spread the ears on the race retaining ring with snap ring pliers
  12.  
  13. Remove the CV joint assembly from the halfshaft bar.
  14.  
  15. Remove the halfshaft outboard seal from the halfshaft bar.
  16.  
  17. Discard the old outboard seal.
  18.  
  19. Place a brass drift against the CV joint cage.
  20.  
  21. Tap gently on the brass drift with a hammer in order to tilt the cage.
  22.  
  23. Remove the first chrome alloy ball when the CV joint cage tilts.
  24.  
  25. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball.
  26.  
  27. Repeat this process to remove all 6 of the balls.
  28.  
  29. Pivot the CV joint cage and the inner race 90 degrees to the center line of the outer race. At the same time, align the cage windows with the lands of the outer race.
  30.  
  31. Lift out the cage and the inner race.
  32.  
  33. Remove the inner race from the cage by rotating the inner race upward.
  34.  
  35. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates:
    1. The inner and outer race assemblies.
    2.  
    3. The CV joint cage.
    4.  
    5. The chrome alloy balls.
    6.  

  36.  
  37. Dry all the parts.
  38.  
  39. Check the CV joint assembly for the following items:
    1. Unusual wear.
    2.  
    3. Cracks.
    4.  
    5. Damage.
    6.  

  40.  
  41. Replace any damaged parts.
  42.  
  43. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).
  44.  

To install:

Click image to see an enlarged view

Fig. Install the new small eared clamp (2) on the neck of the outboard seal (1). Do not crimp. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3)


NOTE
Place a towel in the vise before inserting the halfshaft.

  1. Mount the halfshaft into a vise.
  2.  
  3. Install the new small eared clamp (2) on the neck of the outboard seal (1). Do not crimp.
  4.  
  5. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3).

    Click image to see an enlarged view

    Fig. Crimp the eared clamp (1) using Drive Axle Seal Clamp Pliers such as J 35910 , a breaker bar, and a torque wrench.

  6.  
  7. Crimp the eared clamp using Drive Axle Seal Clamp Pliers such as J 35910, a breaker bar, and a torque wrench.
  8.  
  9. Tighten the eared clamp to 100 ft. lbs. (136 Nm).
  10.  
  11. Check the gap dimension, continue tightening until the gap dimension is reached.
  12.  
  13. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race.
  14.  
  15. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race aligned with the windows of the cage and insert the inner race into the cage.
  16.  
  17. Hold the cage and the inner race 90 degrees to centerline of the outer race and align the cage windows with the lands of the outer race.
    NOTE
    Be sure that the retaining ring side of the inner race faces the halfshaft bar.

  18.  
  19. Place the cage and the inner race into the outer race.
  20.  
  21. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball.
  22.  
  23. Repeat this process until all 6 balls are in place.
  24.  
  25. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease.
  26.  
  27. Push the CV joint onto the halfshaft bar until the retaining ring is seated in the groove on the halfshaft bar.
    NOTE
    The outboard seal must not be dimpled, stretched or out of shape in any way. If the outboard seal is not shaped correctly, equalize the pressure in the outboard seal and shape the seal properly by hand.

  28.  
  29. Slide large diameter of the outboard seal with the large seal retaining clamp in place over the outside of the CV joint outer race and locate the seal lip in the groove on the CV joint outer race.

    Click image to see an enlarged view

    Fig. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 5/6(1.9mm).

  30.  
  31. Crimp the seal retaining clamp (using Drive Axle Seal Clamp Pliers such as J 35910. Tighten clamp to 130 ft. lbs. (174 Nm).
  32.  
  33. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 5 / 6 (1.9mm).
  34.  

Removal & Installation



  1. Raise and suitably support the vehicle.
  2.  
  3. Remove the wheel and the tire.
  4.  
  5. Remove the front wheel drive shaft nut.
  6.  
  7. Remove the outer tie rod assembly from the steering knuckle.
  8.  
  9. Remove the ball joint from the steering knuckle.
    NOTE
    In the following procedure, the wheel drive shaft nut can be partially re-installed to protect the threads.

  10.  
  11. Using a hub spindle remover such as J 42129 , remove the front wheel drive axle from the front wheel drive shaft bearing.
  12.  
  13. Install a seal protector such as J-44394 must be installed into the differential output shaft seal prior to removing the wheel drive shaft.
  14.  
  15. Remove the drive shaft from the spindle and differential.
  16.  

To install:

Click image to see an enlarged view

Fig. A seal protector such as J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft


NOTE
A seal protector such as J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the tool as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.

  1. Install a seal protector such as J-44394 into the differential output shaft seal.
    NOTE
    In order to prevent lubricant leaks, use care when installing the wheel drive shaft to the differential. Do not damage the oil seal. Replace the oil seal if it becomes nicked, distorted, or otherwise damaged. a seal protector such as J-44394 Carefully install the wheel drive shaft into the differential until the splines are past the seal protector.

  2.  
  3. Carefully remove the seal protector from the differential output shaft seal. Carefully continue installing the wheel drive shaft into the differential until the retaining ring is fully seated. Verify the front wheel drive shaft retaining ring is properly seated by grasping the inner housing and pull the inner housing outward. Do not pull on the front wheel drive axle shaft. The front wheel drive axle will remain in place when the front wheel drive shaft retaining ring is properly seated.
  4.  
  5. Install the front wheel drive shaft into the front wheel bearing.
  6.  
  7. Connect the ball joint to the steering knuckle.
  8.  
  9. Connect the outer tie rod assembly to the steering knuckle.
  10.  
  11. Install a new wheel drive shaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning. Tighten the nut to 159 ft. lbs. (215 Nm).
  12.  
  13. Install the wheel and the tire.
  14.  
  15. Lower the vehicle.
  16.  
  17. Inspect the transaxle fluid level.
  18.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the wheelhouse panel from the vehicle.
  6.  
  7. Insert a punch or brass drift in the brake rotor so that the brass drift or punch rest against the brake caliper mounting bracket.
  8.  
  9. Using a breaker bar and socket, loosen the wheel drive shaft nut.
    NOTE
    DO NOT re-use the wheel drive shaft nut, discard and use NEW.

  10.  
  11. Remove the wheel drive shaft nut.
  12.  
  13. Using the appropriate tool, remove the wheel drive shaft from the steering knuckle.
    NOTE
    In the following service procedure, it is NOT necessary to completely remove the tie rod end. Only remove the tie rod end form the steering knuckle ONLY.

  14.  
  15. Remove the outer tie rod end from the steering knuckle. R
  16.  
  17. Remove the stabilizer shaft link at the stabilizer bar and secure.
  18.  
  19. Remove the lower ball joint from the steering knuckle.
  20.  
  21. Remove and relocate the suspension module to the side and secure.
    NOTE
    The following service procedure can be used on vehicles that are Front Wheel Drive (FWD) left side only, as well as vehicles equipped with All Wheel Drive (AWD).

  22.  
  23. Assemble the axle shaft removal tool as illustrated.

    Click image to see an enlarged view

    Fig. Front axle shaft removal tool-Outlook

  24.  
  25. Using the axle shaft removal tool, disengage the wheel drive shaft enough to install a seal protector such as J-44394.
    NOTE
    A seal protector such as J-44394J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.

  26.  
  27. Carefully install a seal protector such as J-44394 over the wheel drive shaft.
  28.  
  29. Carefully slide a seal protector such as J-44394 into the differential output shaft seal.
  30.  
  31. Remove the wheel drive shaft from the vehicle.
  32.  

To install:


NOTE
A seal protector such as J-44394 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install J-44394 as indicated may cause the splines of the wheel drive shaft to cut the differential output seal.

  1. If previously removed, carefully install a seal protector such as J-44394 into the differential output shaft seal.
  2.  
  3. In order to prevent lubricant leaks, use care when installing the wheel drive shaft to the differential.
  4.  
  5. Do not damage the oil seal. Replace the oil seal if it becomes nicked, distorted, or otherwise damaged.
  6.  
  7. Carefully install the wheel drive shaft into the differential until the splines are past the seal protector such as J-44394 .
  8.  
  9. Carefully remove the seal protector from the differential output shaft seal.
  10.  
  11. Carefully continue installing the wheel drive shaft until the retaining ring is fully seated.
  12.  
  13. Verify the front wheel drive shaft retaining ring is properly seated. Grasp the inner housing and pull the inner housing outward. Do not pull on the front wheel drive axle shaft. The front wheel drive axle will remain in place when the front wheel drive shaft retaining ring is properly seated.
  14.  
  15. Install the wheel drive shaft into suspension module.
  16.  
  17. Install the lower ball joint in the steering knuckle.
  18.  
  19. Install the outer tie rod end to the steering knuckle.
  20.  
  21. Install the stabilizer link to the stabilizer bar.
  22.  
  23. Install the wheel drive shaft nut, tighten by hand.
  24.  
  25. Insert a brass drift or punch in the brake rotor so that it rest against the brake caliper mounting
  26.  
  27. Using a torque wrench and socket, tighten the wheel drive shaft nut to 151 ft. lbs. (205 Nm).
  28.  
  29. Install the wheel house panel on the vehicle.
  30.  
  31. Install the tire and wheel.
  32.  
  33. Remove the support and lower the vehicle.
  34.  
  35. Check the fluid level of the transmission
  36.