REMOVAL & INSTALLATION
See Figures 1 through 9
Do NOT begin this procedure unless the following parts are available:
Once removed, these parts must not be reused during assembly. Their torque holding ability or retention capability is diminished during removal.
- Remove the wheel cover/hub cover from the wheel and tire assembly. Loosen the hub retainer nut and the lug nuts.
- Raise the vehicle and support safely.
- Remove the wheel and tire assembly. Remove the hub retainer nut and washer and discard the hub nut.
- Remove the nut from the ball joint-to-steering knuckle attaching bolts. Drive the bolt out of the steering knuckle using a punch and hammer. Discard the bolt and nut.
- If equipped with ABS, remove the anti-lock brake sensor and position aside.
- Separate the ball joint from the steering knuckle using a suitable prybar. Position the end of the prybar outside of the bushing pocket to avoid damage to the bushing. Use care to prevent damage to the ball joint boot. Remove the stabilizer bar link at the stabilizer bar.
- Remove the shaft from the hub assembly.
- Support the end of the shaft by suspending it from a convenient underbody component with a piece of wire. Do not allow the shaft to hang unsupported; damage to the outboard CV-joint may occur.
- Using a suitable prytool, release the inboard joint from the transaxle by carefully prying the shaft away and releasing the retaining circlip.
- Remove the halfshaft assembly from the vehicle.
- Install a new circlip on the transaxle stub shaft and/or link shaft. When installing the circlip, start one end in the groove and work the circlip over the stub shaft end into the groove. This will avoid over expanding the circlip.
The circlip must not be re-used. A new circlip must be installed each time the inboard CV-joint is installed into the transaxle differential.
- Carefully align the splines of the inboard CV-joint stub shaft with the splines in the differential. Exerting some force, push the CV-joint into the differential until the circlip is felt to seat in the differential side gear. Use care to prevent damage to the differential oil seal.
A non-metallic mallet may be used to aid in seating the circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard CV-joint stub shaft.
- Carefully align the splines of the outboard CV-joint stub shaft with the splines in the hub and push the shaft into the hub as far as possible.
- Install the hub nut washer and a new hub nut. Manually thread the retainer onto the CV-joint as far as possible.
Install the remaining components in the reverse order of removal. Tighten the following:
Control arm-to-steering knuckle nut and bolt: 50-68 ft. lbs. (68-92 Nm) using a new nut and bolt
- Fill the transaxle to the proper level with the specified fluid.
These vehicles use several different types of joints. Engine size, transaxle type, whether the joint is an inboard or outboard joint, even which side of the vehicle is being serviced could make a difference in joint type. Be sure to properly identify the joint before attempting joint or boot replacement. Look for identification numbers at the large end of the boots and/or on the end of the metal retainer bands.
The 3 types of joints used are the Birfield Joint, (B.J.), the Tripod Joint (T.J.) and the Double Offset Joint (D.O.J.).
Do not disassemble a Birfield joint. Service with a new joint or clean and repack using a new boot kit.
The distance between the large and small boot bands is important and should be checked prior to and after boot service. This is so the boot will not be installed either too loose or too tight, which could cause early wear and cracking, allowing the grease to get out and water and dirt in, leading to early joint failure.
The driveshaft joints use special grease; do not add any grease other than that supplied with the kit.Double Offset Joint
The Double Offset Joint (D.O.J.) is bigger than other joints and, in these applications, is normally used as an inboard joint.
- Remove the halfshaft from the vehicle.
- Side cutter pliers can be used to cut the metal retaining bands. Remove the boot from the joint outer race.
- Locate and remove the large circlip at the base of the joint. Remove the outer race (the body of the joint).
- Remove the small snap-ring and take off the inner race, cage and balls as an assembly. Clean the inner race, cage and balls without disassembling.
- If the boot is to be reused, wipe the grease from the splines and wrap the splines in vinyl tape before sliding the boot from the shaft.
- Remove the inner (D.O.J.) boot from the shaft. If the outer (B.J.) boot is to be replaced, remove the boot retainer rings and slide the boot down and off of the shaft at this time.
- Be sure to tape the shaft splines before installing the boots. Fill the inside of the boot with the specified grease. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot.
- Install the cage onto the halfshaft so the small diameter side of the cage is installed first. With a brass drift pin, tap lightly and evenly around the inner race to install the race until it comes into contact with the rib of the shaft. Apply the specified grease to the inner race and cage and fit them together. Insert the balls into the cage.
- Install the outer race (the body of the joint) after filling with the specified grease. The outer race should be filled with this grease.
- Tighten the boot bands securely. Make sure the distance between the boot bands is correct.
- Install the halfshaft to the vehicle.
- Disconnect the negative battery cable. Remove the halfshaft.
- Use side cutter pliers to remove the metal retaining bands from the boot(s) that will be removed. Slide the boot from the T.J. case.
- Remove the snap-ring and the tripod joint spider assembly from the halfshaft. Do not disassemble the spider and use care in handling.
- If the boot is be reused, wrap vinyl tape around the splined part of the shaft so the boot(s) will not be damaged when removed. Remove the dynamic damper, if used, and the boots from the shaft.
- Double check that the correct replacement parts are being installed. Wrap vinyl tape around the splines to protect the boot and install the boots and damper, if used, in the correct order.
- Install the joint spider assembly to the shaft and install the snap-ring.
- Fill the inside of the boot with the specified grease. Often the grease supplied in the replacement parts kit is meant to be divided in half, with half being used to lubricate the joint and half being used inside the boot. Keep grease off the rubber part of the dynamic damper (if used).
- Secure the boot bands with the halfshaft in a horizontal position. Make sure distance between boot bands is correct.
- Install the halfshaft to the vehicle and reconnect the negative battery cable.