Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Halfshaft

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REMOVAL & INSTALLATION



See Figures 1 through 9

Installation of the halfshafts will require a special tool for the spline alignment of the halfshaft end and the transaxle case. This procedure should not be performed without access to this tool. The Kent Moore tool Number is J-34296 and J-34297.

  1. Raise the front of the vehicle and support it with jackstands.
  2.  
  3. Remove the wheel. Remove the brake caliper assembly. The brake hose does not need to be disconnected from the caliper. Be careful not to depress the brake pedal, or the piston will pop out. Do not twist the brake hose.
  4.  
  5. Pull out the cotter pin from the castellated nut on the wheel hub and then remove the wheel bearing lock nut.
  6.  

Cover the boots with a shop towel or waste cloth so not to damage them when removing the halfshaft.

  1. Separate the halfshaft from the steering knuckle by tapping it with a block of wood and a mallet. It may be necessary to loosen (do not remove) the strut mounting bolts to gain clearance for steering knuckle removal from the halfshaft.
  2.  



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Fig. Fig. 1: Removing the wheel bearing lock-nut



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Fig. Fig. 2: Separating the halfshaft from the steering knuckle



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Fig. Fig. 3: Loose (DO NOT REMOVE) strut mounting nuts



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Fig. Fig. 4: Removing the halfshaft from the steering knuckle



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Fig. Fig. 5: Removing right halfshaft from transaxle



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Fig. Fig. 6: Removing left halfshaft from transaxle - manual transaxle



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Fig. Fig. 7: Removing left halfshaft from transaxle - automatic transaxle



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Fig. Fig. 8: Set special tool along the inner circumference of oil seal transaxle side



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Fig. Fig. 9: Insert halfshaft into transaxle with special tool aligned properly

  1. Remove the tie rod ball joint.
  2.  

Always use a new nut and cotter pin when installing the tie rod ball joint.

  1. On models with a manual transaxle, using a suitable tool, reach through the engine crossmember and carefully tap the right side inner CV-joint out of the transaxle case.
  2.  
  3. If no support bracket is used disregard this step--using a block of wood on an hydraulic floor jack, support the engine under the oil pan if necessary. Remove the support bearing bracket from the engine and then withdraw the right halfshaft if so equipped.
  4.  
  5. On models with manual transaxle, carefully insert a small prybar between the left CV-joint inner flange and the transaxle case mounting surface and pry the halfshaft out of the case. Withdraw the shaft from the steering knuckle and remove it.
  6.  
  7. On models with automatic transaxle, insert a dowel through the right side halfshaft hole (remove the right side halfshaft the same way as on manual transaxle models) and use a small mallet to tap the left halfshaft out of the transaxle case. Withdraw the shaft from the steering knuckle and remove it--refer to the illustrations.
  8.  

Be careful not to damage the pinion mating shaft and the side gear while tapping the left halfshaft out of the transaxle case.

  1. When installing the shafts into the transaxle, use a new oil seal and then install an alignment tool along the inner circumference of the oil seal.
  2.  
  3. Insert the halfshaft into the transaxle, align the serrations and then remove the alignment tool.
  4.  
  5. Push the halfshaft, then press-fit the circular clip on the shaft into the clip groove on the side gear.
  6.  

After insertion, attempt to pull the flange out of the side joint to make sure that the circular clip is properly seated in the side gear and will not come out.

  1. Install support bearing bracket retaining bolts and insert the halfshaft in the steering knuckle if so equipped. Tighten the strut mounting bolts if loosen.
  2.  
  3. Connect the tie rod end in the correct position use new nut and cotter pin.
  4.  
  5. Install the caliper assembly and the wheel bearing lock-nut. Tighten the nut to 174-231 ft. lbs.
  6.  
  7. Install a new cotter pin on the wheel hub and install the wheel.
  8.  
  9. Bleed the brake system if necessary. Road test the vehicle for proper operation.
  10.  

CV-JOINT OVERHAUL



Transaxle Side

See Figures 10, 11, 12, 13, 14 and 15

  1. Remove the halfshaft and mount in a protected jaw vise.
  2.  
  3. Remove the boot bands.
  4.  
  5. Matchmark the slide joint housing and spider assembly to the halfshaft.
  6.  
  7. Remove the slide joint housing from the halfshaft.
  8.  
  9. Remove the spider snap-ring.
  10.  
  11. Remove the spider assembly from the halfshaft.
  12.  
  13. Cover the driveshaft splined end with tape to protect the CV-boot.
  14.  
  15. Remove the CV-boot.
  16.  



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Fig. Fig. 10: Halfshaft assembly



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Fig. Fig. 11: Disassembly halfshaft



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Fig. Fig. 12: Disassembly halfshaft



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Fig. Fig. 13: Installing CV boot - wheel side



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Fig. Fig. 14: Assembly halfshaft



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Fig. Fig. 15: Installing CV boot - transaxle side

To install:
  1. Install the CV-boot with a new boot band.
  2.  
  3. Install the spider assembly. Make sure the matchmarks are aligned properly.
  4.  
  5. Install a new spider snap-ring. Make sure the snap-ring seats evenly in the groove of the shaft.
  6.  
  7. Pack the CV-boot with grease (holds 5.64-6.35 oz. of proper grease--should be 3.82-3.90 inches or 97-99mm in length after packed with grease, see illustrations).
  8.  
  9. Install the remaining boot bands. Tighten and crimp the bands using the proper tool.
  10.  

Wheel Side
  1. Remove the halfshaft and mount in a protected jaw vise.
  2.  
  3. Matchmark the joint assembly to the shaft.
  4.  
  5. Remove the joint assembly (replace the complete joint assembly if damage or deformed) from the shaft using a suitable puller. Install the axle nut to prevent damage to the threads when removing the joint.
  6.  
  7. Remove the boot bands.
  8.  
  9. Cover the halfshaft splined end with tape to protect the CV-boot.
  10.  
  11. Remove the CV-boot.
  12.  

To install:
  1. Install the CV-boot with a new boot band.
  2.  
  3. Install the joint assembly by tapping lightly. Make sure the axle nut is installed to prevent damage to the threads. Make sure the matchmarks are aligned properly.
  4.  
  5. Pack the CV-boot with the proper grade and amount of grease (holds 7.23-7.94 oz. of proper grease--should be 3.78-3.86 inches or 96-98mm in length after packed with grease, see illustrations).
  6.  
  7. Install the remaining boot bands. Tighten and crimp the bands using the proper tool.
  8.  

 
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