GM Corsica/Beretta 1988-1996 Repair Guide

Intermediate shaft

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REMOVAL & INSTALLATION



1988-89 Vehicles

See Figure 1

  1. Raise the car and suitably support.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Drain the transaxle into a suitable container.
  6.  
  7. Install the modified outer seal protector J-34754.
  8.  
  9. Remove the stabilizer shaft from the right control arm.
  10.  
  11. Remove the right ball joint from the knuckle.
  12.  
  13. Disconnect the drive axle from the intermediate axle shaft.
  14.  
  15. Remove the 2 housing to bracket bolts.
  16.  
  17. Remove the bottom bracket to engine bolt and loosen the top bolt, rotate the bracket out of the way.
  18.  
  19. Remove the 3 bolts holding the housing to the transaxle.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the intermediate shaft assembly - 1988-89 vehicles

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. (25 Nm).
  4.  
  5. Rotate the bracket into position and install the bottom bolt, tighten both bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the 2 housing to bracket bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Coat the splines with chassis grease.
  10.  
  11. Attach the drive axle to the intermediate axle shaft.
  12.  
  13. Connect the right ball joint to the knuckle.
  14.  
  15. Install the stabilizer shaft to the right control arm.
  16.  
  17. Remove the modified outer seal protector J-34754.
  18.  
  19. Install the wheel and tire assembly.
  20.  
  21. Lower the car and fill the transaxle with the proper type and amount of fluid.
  22.  

1990 Vehicles
2.3L ENGINE
  1. Install engine support bar J-28467.
  2.  
  3. Raise the car and suitably support.
  4.  
  5. Remove the wheel assembly.
  6.  
  7. Drain the transaxle.
  8.  
  9. Install the modified outer seal protector J-34754.
  10.  
  11. Remove the stabilizer shaft from the right control arm.
  12.  
  13. Remove the right ball joint from the knuckle.
  14.  
  15. Remove the rear engine mount through bolt.
  16.  
  17. Disconnect the drive axle from the intermediate axle shaft.
  18.  
  19. Remove the bolt retaining the intermediate shaft to the engine.
  20.  
  21. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  22.  

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. Install 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.
  14.  
  15. Install the wheel and lower the vehicle.
  16.  
  17. Remove the engine support bar holding fixture.
  18.  
  19. Fill the transaxle with the proper fluid.
  20.  

3.1L ENGINE

See Figure 2

  1. Install engine support bar J-28467.
  2.  
  3. Raise the car and suitably support.
  4.  
  5. Remove the wheel assembly.
  6.  
  7. Drain the transaxle.
  8.  
  9. Install the modified outer seal protector J-34754.
  10.  
  11. Remove the stabilizer shaft from the right control arm.
  12.  
  13. Remove the right ball joint from the knuckle.
  14.  
  15. Disconnect the drive axle from the intermediate axle shaft.
  16.  
  17. Disconnect the rear engine mount.
  18.  
  19. Remove the bolt retaining the intermediate shaft to the engine.
  20.  
  21. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: Intermediate shaft mounting - 1990 3.1L engines

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. 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. Install 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.
  14.  
  15. Install the wheel and lower the vehicle.
  16.  
  17. Remove the engine support bar holding fixture.
  18.  
  19. Fill the transaxle with the proper fluid.
  20.  

1991 Vehicles

See Figures 3 and 4

  1. Install engine support bar J-28467.
  2.  
  3. Raise the car and suitably support.
  4.  
  5. Remove the wheel assembly.
  6.  
  7. Drain the transaxle.
  8.  
  9. Install the modified outer seal protector J-34754.
  10.  
  11. Remove the nut attaching the right stabilizer link to the stabilizer shaft.
  12.  
  13. Remove the right ball joint from the knuckle.
  14.  
  15. Disconnect the drive axle from the intermediate axle shaft and support the drive axle.
  16.  
  17. Disconnect the rear engine mount.
  18.  
  19. Remove the bolt retaining the intermediate shaft support bracket to the engine.
  20.  
  21. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  22.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the intermediate shaft mounting - 1991-92 vehicles with the Isuzu transaxle



Click image to see an enlarged view

Fig. Fig. 4: Intermediate shaft removal and installation - 1991-92 vehicles except with the Isuzu transaxle

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 support bracket to the engine and tighten hand tight.
  4.  
  5. Install the rear engine mount.
  6.  
  7. Torque the intermediate shaft support bracket bolt to 37 ft. lbs. (50 Nm).
  8.  
  9. Coat the intermediate axle shaft with chassis grease and install the intermediate axle shaft to the drive axle. Place a suitable tool into the groove on the joint housing and tap until seated.
  10.  


WARNING
Be careful not to damage the axle seal or dislodge the garter spring when installing.

  1. Install the right ball joint to the knuckle. Tighten the nut to 26 ft. lbs. (35 Nm) plus a 60 degree rotation and install the cotter pin.
  2.  
  3. Install the nut attaching the stabilizer link to the stabilizer shaft. Tighten to 13 ft. lbs. (17 Nm) for all except GTZ models and to 70 ft. lbs. (95 Nm) for GTZ models.
  4.  
  5. Remove the seal protector tool.
  6.  
  7. Install the wheel and lower the vehicle.
  8.  
  9. Remove the engine support bar holding fixture.
  10.  
  11. Fill the transaxle with the proper fluid.
  12.  

1992-96 Vehicles

See Figures 3 and 4

  1. Install engine support bar J-28467.
  2.  
  3. Raise the car and suitably support.
  4.  
  5. Remove the wheel assembly.
  6.  
  7. Drain the transaxle.
  8.  
  9. Install the modified outer seal protector J-34754.
  10.  
  11. Remove the stabilizer shaft from the right control arm.
  12.  
  13. Remove the right ball joint from the knuckle.
  14.  
  15. Remove the rear engine mount through bolt.
  16.  
  17. Disconnect the drive axle from the intermediate axle shaft.
  18.  
  19. Remove the bolt retaining the intermediate shaft to the engine.
  20.  
  21. Carefully disengage the intermediate axle shaft from the transaxle and remove the intermediate shaft assembly.
  22.  

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 35 ft. lbs. (47 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. Install 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.
  14.  
  15. Install the wheel and lower the vehicle.
  16.  
  17. Remove the engine support bar holding fixture.
  18.  
  19. Fill the transaxle with the proper fluid.
  20.  

CV- JOINT OVERHAUL



See Figures 5 and 6

1988-90 Tri-Pot Design

All driveshafts except the left side inboard joint of the automatic transaxles incorporates a male spline and interlocks with the transaxle gears through the use of a barrel type snap rings. The left side inboard shaft attachment on the automatic transaxle, utilizes a female spline which installs over a stub shaft protruding from the transaxle.

For all overhaul procedures for the 1988-90 Tri-Pot type drive axles, please refer to the illustrated procedures.

1988-96 Cross Groove and 1991-96 Tri-Pot Design

The inner joint on cars with the HM-282, 5TM40 and NVT-550 5-speed transaxles, is a Cross-Groove type. All other applications use the Tri-Pot inner joint.

The following overhaul procedures incorporate both designs, unless otherwise noted.



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the Cross-Groove type drive axle - 1988-96 vehicles



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the Tri-Pot type drive axle - 1988-96 vehicles

Outer Deflector Ring

See Figures 7 and 8

  1. Remove the halfshaft/drive axle from the vehicle.
  2.  
  3. Clamp the halfshaft in a soft jawed vise.
  4.  
  5. Using a brass drift and a hammer, remove the deflecting ring from the CV outer race.
  6.  



Click image to see an enlarged view

Fig. Fig. 7: Use a brass drift and hammer to remove the deflector ring - Cross-Groove and 1991-96 Tri-Pot type halfshafts

To install:
  1. Position and square up the deflecting ring at press diameter of CV outer race.
  2.  
  3. Using a 3 in. (76mm) pipe coupling, M24 1.5 nut a fabricated sheet metal sleeve, tighten the nut until the deflector bottoms against the shoulder of the outer CV-joint.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Installation of the deflector ring - Cross-Groove and 1991-96 Tri-Pot type halfshafts

Outer Joint Seal

See Figures 9, 10 and 11

  1. Remove the large seal retaining clamp from the CV joint with a side cutter and discard.
  2.  
  3. Use a side cutter to remove the small seal retaining clamp from the axle shaft with a side cutter and discard.
  4.  
  5. Separate the joint seal from the CV join race at large diameter and slide the seal away from the joint along the axle shaft.
  6.  



Click image to see an enlarged view

Fig. Fig. 9: CV-joint axle separation - Cross-Groove and 1991-96 Tri-Pot drive axles

  1. Wipe the excess grease from the face of the CV joint inner race.
  2.  
  3. Spread the ears on the race retaining ring with snap ring pliers and remove the CV joint from the axle shaft.
  4.  
  5. Remove the seal from the axle shaft.
  6.  
  7. Disassemble the joint and flush the grease prior to installing a new seal.
  8.  

To install:
  1. Install the small retaining clamp on the neck of the new seal, but do not crimp.
  2.  
  3. Slide the seal onto the axle shaft and position the neck of the seal in the seal groove on the axle shaft.
  4.  
  5. Crimp the seal retaining clamp with J 35910 seal clamp tool or equivalent, to 100 ft. lbs. (136 Nm).
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Use the proper tool to crimp the retaining clamp

  1. Place approximately half of the grease provided in the seal kit, inside the seal and repack the CV joint with the remaining grease.
  2.  
  3. Push the CV joint onto the axle shaft until the retaining ring is seated in the groove on the axle shaft.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: CV-joint-to-axle installation - Cross-Groove and 1991-96 Tri-Pot drive axles

  1. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of the CV joint race and locate the lip of the seal in the groove on the race.
  2.  


WARNING
The seal must not be dimpled or out of shape in any way. If it is not shaped correctly, equalize pressure in the seal and reshape properly by hand.

  1. Crimp the seal retaining clamp with J 35910 seal clamp tool or equivalent, to 130 ft. lbs. (176 Nm).
  2.  

Outer Joint Assembly

See Figures 12, 13 and 14

  1. Remove the outer joint seal as outlined earlier.
  2.  
  3. Using a brass drift and a hammer, lightly tap on the inner race cage until it has tilted sufficiently to remove one of the balls. Remove the other balls in the same manner.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: CV-joint ball removal - Cross-Groove and 1991-96 Tri-Pot drive axles

  1. Pivot the cage 90 degrees and, with the cage ball windows aligned with the outer joint windows, lift out the cage and the inner race.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Outer race and cage separation

  1. The inner race can be removed from the cage by pivoting it 90° and lifting out. Clean all parts thoroughly and inspect for wear.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Inner race and cage separation

To install:
  1. To install, put a light coat of the grease provided in the rebuilding kit onto the ball grooves of the inner race and outer joint.
  2.  
  3. Install the parts in the reverse order of removal.
  4.  

Make sure that the retaining ring side of the inner race faces the axle shaft.

  1. Install the outer seal as outlined earlier.
  2.  

Cross Groove Joint Seal

See Figures 15, 16, 17 and 18

  1. Cut the seal retaining clamps with a side cutter.
  2.  
  3. Separate the seal from the C/G joint race at the large diameter and slide the seal away from the joint along the axle shaft.
  4.  



Click image to see an enlarged view

Fig. Fig. 15: Cross-Groove (C/G) joint and axle separation

  1. Wipe the excess grease from the C/G joint inner race.
  2.  
  3. Spread the ears on the retaining ring with snap ring pliers and remove the C/G joint from the axle shaft.
  4.  
  5. Remove the seal from the axle shaft.
  6.  
  7. Remove the seal from the shaft.
  8.  

The cross-groove joint design uses precision grinding and selected dimensional component fits for proper assembly and operation. Due to its complexity, disassembly is not recommended.

  1. Flush the grease from the joint prior to installing a new seal.
  2.  

To install:
  1. Install the small retaining clamp on the neck of the new seal, but do not crimp yet.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: Seal retaining clamp installation

  1. Slide the seal onto the axle shaft and position the neck of the seal in the seal groove on the axle shaft.
  2.  
  3. Crimp the seal retaining clamp with J 35910 seal clamp tool or equivalent, to 100 ft. lbs. (136 Nm).
  4.  
  5. Place approximately half of the grease provided in the seal kit, inside the seal and repack the C/G joint with the remaining grease.
  6.  
  7. Push the C/G joint onto the axle shaft until the retaining ring is seated in the groove on the axle shaft.
  8.  



Click image to see an enlarged view

Fig. Fig. 17: Cross-Groove joint-to-axle assembly

  1. Slide the large diameter of the seal over the outside of the C/G joint and locate the lip of the seal in the groove on ball retainer.
  2.  



Click image to see an enlarged view

Fig. Fig. 18: Cross-Groove seal installation measurement


WARNING
The seal must not be dimpled or out of shape in any way. If it is not shaped correctly, equalize pressure in the seal and reshape properly by hand.

  1. Crimp the seal retaining clamp with J 35910 seal clamp tool or equivalent, to 130 ft. lbs. (176 Nm).
  2.  

 
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