Short Output Shaft Replacement

Fig. 9 Short Output Shaft Removal:

Fig. 10 Lowering Engine Cradle:

It is necessary to remove differential cover to replace short output shaft inner seal.

1. Raise and support vehicle.
2. Remove differential drain plug, and drain lubricant.
3. Using a suitable punch, remove roll pin attaching driveshaft to output shaft.
4. Using a screwdriver, remove output shaft dust cover.
5. Loosen retaining bolt (C), then pull output shaft and bearing (D) out of differential cover, Fig. 9.
6. Using a screwdriver, pry outer seal from cover.
7. Remove differential as follows:
a. Remove differential fill plug, and differential cover bolts.
b. Using suitable jack, raise transaxle as far as possible.
c. Loosen engine cradle bolts until there is a 1/2 to 7/8 inch space between cradle and side sill, as shown in Fig. 10. Do not completely remove cradle bolts.
d. Disconnect oil filler tube, and remove differential cover and ring gear assembly from transaxle case.
8. Using a screwdriver, remove inner seal from case. Do not damage seal bore with screwdriver when removing seal.
9. Install new inner seal using seal installer tool No. 6174 and drive handle No. C-6091 or C-4171 or equivalents.
10. Install differential as follows:
a. Install ring gear assembly.
b. Install new seal on differential cover, then install cover on transaxle case. Torque cover attaching bolts to 17 lb-ft.
c. Torque engine cradle bolts to 44 lb-ft, then remove jack from transaxle.
11. Ensure output shaft bearing is packed full of suitable grease prior to shaft installation. Install output shaft and bearing in cover, then install retaining nut and torque to 18 lb-ft.
12. Using seal installer tool No. 6152 or equivalent, install outer seal.
13. Using dust cover installing tool No. 6156 or equivalent and a screwdriver handle, install dust cover over outer seal.
14. Install differential drain plug and torque to 18 lb-ft. Fill differential with synthetic type, 75W-140 hypoid gear lubricant. Add lubricant until it flows from fill hole, then install fill plug and torque to 37 lb-ft.
15. Attach driveshaft to output shaft. Using suitable punch, install driveshaft roll pin.
16. Install underbody splash shield, then lower vehicle.