ION 2006-2007

Halfshafts

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CV-Boots Inspection



The CV (Constant Velocity) boots should be checked for damage each time the oil is changed and any other time the vehicle is raised for service. These boots keep water, grime, dirt and other damaging matter from entering the CV-joints. Any of these could cause early CV-joint failure, which can be expensive to repair. Heavy grease thrown around the inside of the front wheel(s) and on the brake caliper can be an indication of a torn boot. Thoroughly check the boots for missing clamps and tears. If the boot is damaged, it should be replaced immediately. Please refer to Section 7 for procedures.

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Fig. CV-boots must be inspected periodically for damage



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Fig. A torn boot should be replaced immediately

CV-Joints



Overhaul
Inner
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Halfshaft
     
    Small boot clamp ring using a side cutter and discard
     
    Earless clamp and discard
     
    Large CV-joint boot clamp using a side cutter and discard
     
    CV-joint boot by sliding it away from the tri-pod joint
     
    Tri-pod housing from the tri-pod spider
     
    Inboard spacer ring slide it rearward on the shaft
     
    Outboard retaining ring
     
    Tri-pod joint spider assembly
     
    Inboard spacer ring and CV-joint boot
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    The clamp must be positioned correctly during crimping to ensure a correct seal.



    Small boot clamp onto the neck of the inboard boot but do not tighten
     
    Inboard boot onto the shaft
     

  2.  
  3. Use boot clamp installer SA9203C to tighten the clamp making sure the end gap on the clamp does not exceed 0.118 inch (3mm)
    NOTE
    The joint must be assembled with the convoluted retainer in position to avoid boot damage.


    NOTE
    Make sure the boot lies flat against the trilobal bushing.



    Spider assembly past the retaining ring groove until it is seated against the shoulder
     
    Spider retaining ring
     
    1 / 2 kit grease into the boot
     
    1 / 2 kit grease into the tri-pod housing
     



    Tri-lobal housing bushing making sure it is flush with the housing
     
    New large seal clamp onto the CV-joint boot and slide the housing over the tri-pod joint spider assembly
     
    CV-joint boot/clamp, slide it into place, over the trilobal tri-pod bushing with the seal lip in the groove
     

  4.  
  5. Position the CV-joint boot so it measures 4.9 in. (125mm).
  6.  
  7. Using a boot clamp installer SA9161C tighten the large clamp.
  8.  
  9. Install the halfshaft and the front wheel.
  10.  

Outer
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Axle shaft from the vehicle
     
    Large CV boot retaining clamp
     
    Small CV boot retaining clamp
     
    CV boot from the joint
     
    Axle shaft retaining ring
     
    Outer joint from the axle shaft
     
    CV boot
     

  4.  
  5. Disassemble the chrome alloy balls from the CV-joint cage as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Remove the 1st chrome alloy ball from the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Remove the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are removed.
    10.  

  6.  
  7. Disassemble the CV-joint cage and inner race as follows:
    1. Pivot the cage and race 90 degrees to the center line of the outer race.
    2.  
    3. Align the cage windows with outer race lands.
    4.  
    5. Remove the cage from the outer race.
    6.  
    7. Rotate the inner race upward and remove it from the cage.
    8.  

  8.  

To install:

  1. Lubricate the parts with a light coat of grease.
  2.  
  3. Assemble the CV-joint cage and inner race, as follows:
    1. Rotate the inner race 90 degrees to the cage centerline.
    2.  
    3. Align the cage windows with inner race lands.
    4.  
    5. Insert the inner race into the cage by rotating the inner race downward.
    6.  
    7. Insert the cage/inner race into the outer race.
    8.  

  4.  
  5. Assemble the chrome alloy balls into the CV-joint cage, as follows:
    1. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage.
    2.  
    3. Insert the 1st chrome alloy ball into the cage.
    4.  
    5. Tilt the cage in the opposite direction.
    6.  
    7. Insert the opposite chrome alloy ball.
    8.  
    9. Repeat the procedure until all 6 balls are inserted.
    10.  

  6.  
  7. Install 1 / 2 of the grease provided, into the CV-joint.
  8.  
  9. Install or connect the following:

    Small CV boot retaining ring
     
    CV boot on the halfshaft
     
    New retaining ring on the halfshaft
     
    Large ring clamp on the CV boot
     
    Outer joint onto the axle shaft
     
    Retaining ring into the outer race
     

  10.  
  11. Install the remaining grease into the CV boot.
  12.  
  13. Position the CV boot and the small boot clamp.
  14.  
  15. Crimp the small boot clamp making sure not exceed an end gap of 0.118 inch (3mm).
  16.  
  17. Position and crimp in place the large boot clamp making sure not exceed an end gap of 0.118 inch (3mm)
  18.  
  19. Install the halfshaft in the vehicle.
  20.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the wheel assembly.
  4.  
  5. Remove the wheel drive shaft nut by inserting a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning.
  6.  
  7. Carefully loosen the wheel drive shaft splines from the wheel bearing/hub assembly using a wood block and a hammer. The nut can be partially reinstalled to protect the threads.
    NOTE
    Be sure that the wheel speed sensor wiring harness is repositioned away from the ball joint after disconnecting the electrical connector from the sensor.

  8.  
  9. Disconnect the ball joint from the steering knuckle.
  10.  
  11. Separate the wheel drive shaft from the wheel bearing/hub assembly, then support the shaft assembly.
  12.  
  13. Using slide hammer SA 9173G and drive shaft removal tool J 45341, remove the shaft from the transmission.
  14.  

To install:

  1. Inspect the transaxle output shaft seal for damage and/or contamination and replace if necessary.
  2.  
  3. Install the a Seal Protector Tool SA91112T.
  4.  
  5. Install the wheel drive shaft into the transaxle until the drive shaft splines are past the seal, remove the seal protector tool.
  6.  
  7. Verify that the wheel drive shaft is properly engaged by grasping the inner tripod housing and pull the inner housing outward. Do NOT pull on the wheel drive axle shaft. The wheel drive shaft will remain firmly in place when properly engaged.
  8.  
  9. Install the wheel drive shaft to the wheel bearing/hub assembly.
  10.  
  11. Connect the ball joint to the steering knuckle and tighten as follows:
    1. First Pass: Tighten the nut to 37 ft. lbs. (50 Nm).
    2.  
    3. Reverse the nut 3 / 4 of a turn.
    4.  
    5. Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm) plus an additional 30 degrees.
    6.  

  12.  
  13. Install the wheel drive shaft nut to the wheel drive shaft assembly and tighten to 155 ft. lbs. (210 Nm).
  14.  
  15. Install the wheel assembly.
  16.  
  17. Inspect the transaxle fluid level and wheel alignment.
  18.  

 
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