ION, L-Series, S-Series 1999-2005

Removal & Installation


  1. Before servicing the vehicle, refer to the precautions section.
  3. Remove or disconnect the following:

    Stabilizer link

  5. Insert a drift into the caliper to prevent the rotor from turning and remove the half shaft nut.

    Tie rod end from the steering knuckle
    Wheel speed sensor connection. Make sure to position the harness away from the ball joint after disconnecting.
    Lower ball joint from the steering knuckle
    Drive shaft from the knuckle using a hammer and a block of wood. Partially install the nut before striking the wood with the hammer to prevent thread damage.

  7. Using slide hammer SA 9173G and drive shaft removal tool J 45341, remove the shaft from the transmission.

To install:

  1. Apply Output Shaft Lubricant 7847638, to the splines of the output shaft, if equipped with an automatic transaxle.
  3. Install or connect the following:

    New stub shaft retaining ring
    Halfshaft to the transaxle after installing a Seal Protector Tool SA91112T

  5. Remove the seal protector tool after the splines have passed the oil seal.
  7. Install or connect the following:

    Fully seat the halfshaft into the transaxle
    Outer end of the halfshaft to the wheel hub with a new washer and nut
    Ball joint to the steering knuckle. Torque the fastener to 44 ft. lbs. (60 Nm), then an additional 30 degree turn.
    Tie rod end to the steering knuckle. When seated properly, torque the fastener to 15 ft. lbs. (20 Nm) plus an additional 180 degree turn.
    Halfshaft to wheel nut. Torque the nut to 81 ft. lbs. (110 Nm
    Cotter pin
    Stabilizer link and tighten the nut to 63 ft. lbs. (85 Nm)

  9. Top off the transaxle with the proper fluid.
  11. Check and adjust the front end alignment as necessary.