GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Intermediate shaft

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REMOVAL & INSTALLATION



2.8L and 3.1L Engines
1987 VEHICLES

See Figure 1

  1. Install engine support bar J-28467.
  2.  
  3. Raise and safely support the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the the intermediate shaft removal - 1987 2.8L engine shown

  1. Remove the wheel and tire assembly.
  2.  
  3. Drain the transaxle.
  4.  
  5. Install the modified outer seal protector J-34754 or equivalent.
  6.  
  7. Remove the stabilizer shaft from the right control arm.
  8.  
  9. Separate the right ball joint from the steering knuckle.
  10.  
  11. Disconnect the drive axle (halfshaft) from the intermediate axle shaft.
  12.  
  13. Unfasten the two housing-to-bracket bolts.
  14.  
  15. Remove the bottom bracket-to-engine bolt and loosen the top bolt, then rotate the bracket out of the way.
  16.  
  17. Unfasten the 3 bolts holding the housing to the transaxle.
  18.  
  19. Carefully disengage the intermediate axle shaft from the transaxle, then remove the intermediate shaft assembly.
  20.  

To install:
  1. Place the intermediate shaft into position and lock the intermediate axle shaft into the transaxle.
  2.  
  3. Install the 3 bolts holding the housing to the transaxle and tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. Rotate the bracket into position and install the bottom bolt, then tighten both bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the two housing to bracket bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Coat the splines with chassis grease.
  10.  
  11. Connect the drive axle to the intermediate axle shaft.
  12.  
  13. Fasten the right ball joint to the knuckle.
  14.  
  15. Install the stabilizer shaft to the right control arm.
  16.  
  17. Install the wheel and tire assembly.
  18.  
  19. Carefully the car, then fill the transaxle with the proper fluid.
  20.  

1988-94 VEHICLES

See Figures 2, 3 and 4

  1. Install engine support bar J-28467 or equivalent.
  2.  
  3. Raise and safely support the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Intermediate shaft assembly removal - 1988-90 2.8L and 3.1L engines



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Fig. Fig. 3: Intermediate shaft assembly removal - 1991-92 2.8L and 3.1L engines



Click image to see an enlarged view

Fig. Fig. 4: View of the intermediate shaft - 1994 3.1L engine equipped with the NVT550 manual transaxle

  1. Remove the right wheel and tire assembly.
  2.  
  3. Install the modified outer seal protector J-34754 or place shop towels underneath the outer joint to protect it from any sharp edges.
  4.  
  5. Remove the stabilizer shaft from the right control arm.
  6.  
  7. Remove the right ball joint from the knuckle.
  8.  
  9. For 1992-94 vehicles, remove the rear engine mount through-bolt.
  10.  
  11. Disconnect the drive axle from the intermediate axle shaft.
  12.  
  13. For 1988-91 vehicles, remove the rear engine mount.
  14.  
  15. Remove the bolt(s) retaining the intermediate shaft to the engine.
  16.  
  17. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  18.  

To install:
  1. Place the intermediate shaft assembly into position and lock the intermediate axle shaft into the transaxle.
  2.  
  3. Install the bolt retaining the intermediate shaft to the engine and tighten to 38 ft. lbs. (52 Nm).
  4.  
  5. For 1988-91 vehicles, install the rear engine mount.
  6.  
  7. Coat the intermediate axle shaft with chassis grease and install the intermediate axle shaft to the drive axle.
  8.  
  9. For 1992-94 vehicles, install the rear engine mount through-bolt.
  10.  
  11. Fasten the right ball joint to the knuckle.
  12.  
  13. Install the stabilizer shaft to the right control arm.
  14.  
  15. Remove the seal protector tool or shop towels, as applicable.
  16.  
  17. Install the wheel and tire assembly, then carefully lower the vehicle.
  18.  
  19. Remove the engine support bar holding fixture.
  20.  
  21. Fill the transaxle with the proper fluid.
  22.  

2.0L (VIN M and H) Engines
1987 VEHICLES

See Figure 5

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel and tire assembly.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Intermediate shaft removal and installation - 1987 2.0L (VIN M) engine shown

  1. Remove the stabilizer shaft from the right control arm.
  2.  
  3. Using tool J 29330, or equivalent, separate the right ball joint from the knuckle.
  4.  
  5. Disconnect the drive axle from the intermediate axle shaft.
  6.  
  7. Detach the detonation sensor and connection.
  8.  
  9. Remove the power steering pump brace.
  10.  
  11. Unfasten the 3 intermediate shaft bracket bolts, then remove the intermediate shaft from the vehicle.
  12.  

To install:
  1. Install intermediate shaft, secure using the 3 bolts, then tighten the bolts to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the power steering pump brace.
  4.  
  5. Install the detonation sensor.
  6.  
  7. Coat the splines of the intermediate shaft with chassis grease.
  8.  
  9. Attach the drive axle to the intermediate axle shaft.
  10.  
  11. Connect the right ball joint to the knuckle. Tighten to 45 ft. lbs. (60 Nm) and install a new cotter pin.
  12.  
  13. Install the stabilizer shaft to the right control arm.
  14.  
  15. Install the wheel and tire assembly.
  16.  
  17. Carefully lower the vehicles.
  18.  

1988-90 VEHICLES

See Figure 6

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the right wheel and tire assembly.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Intermediate shaft removal and installation - 1990 2.0L (VIN M) engine shown

  1. Drain the transaxle.
  2.  
  3. Install the modified outer seal protector J-34754.
  4.  
  5. Remove the stabilizer shaft from the right control arm.
  6.  
  7. Separate the right ball joint from the knuckle.
  8.  
  9. Disconnect the drive axle from the intermediate axle shaft.
  10.  
  11. Unfasten the bracket-to-engine bolts and the stud, then carefully disengage the intermediate axle shaft from the transaxle and remove the assembly.
  12.  

To install:
  1. Place the intermediate shaft into position and lock the intermediate axle shaft into the transaxle.
  2.  
  3. Install the bracket to engine bolts and one stud and tighten to 35 ft. lbs. (47 Nm).
  4.  
  5. Coat the splines of the intermediate shaft with chassis grease.
  6.  
  7. Attach the drive axle to the intermediate axle shaft.
  8.  
  9. Fasten the right ball joint to the knuckle.
  10.  
  11. Install the stabilizer shaft to the right control arm.
  12.  
  13. Install the wheel and tire assembly.
  14.  
  15. Carefully lower the car and fill the transaxle with the proper fluid.
  16.  

1991-94 VEHICLES

See Figure 7

  1. Install engine support bar J-28467 or equivalent.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the right wheel and tire assembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 7: View of the intermediate shaft - 1994 2.0L engine equipped with the Isuzu manual transaxle

  1. Install the modified outer seal protector J-34754 or place shop towels underneath the outer joint to protect it from any sharp edges.
  2.  
  3. Remove the stabilizer shaft from the right control arm.
  4.  
  5. Remove the right ball joint from the knuckle.
  6.  
  7. Remove the rear engine mount through-bolt.
  8.  
  9. Disconnect the drive axle from the intermediate axle shaft.
  10.  
  11. Remove the bolt(s) retaining the intermediate shaft to the engine.
  12.  
  13. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  14.  

To install:
  1. Place the intermediate shaft assembly into position and lock the intermediate axle shaft into the transaxle.
  2.  
  3. Install the bolt retaining the intermediate shaft to the engine and tighten to 38 ft. lbs. (52 Nm).
  4.  
  5. Coat the intermediate axle shaft with chassis grease and install the intermediate axle shaft to the drive axle.
  6.  
  7. Install the rear engine mount through-bolt.
  8.  
  9. Fasten the right ball joint to the knuckle.
  10.  
  11. Install the stabilizer shaft to the right control arm.
  12.  
  13. Remove the seal protector tool or shop towels, as applicable.
  14.  
  15. Install the wheel and tire assembly, then carefully lower the vehicle.
  16.  
  17. Remove the engine support bar holding fixture.
  18.  
  19. Fill the transaxle with the proper fluid.
  20.  

 
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