Axle Shaft: Service and Repair

REMOVAL

Three different types of side gear (output) shafts may be used. Different outer and inner constant velocity joints are used on the driveshafts. After removing the driveshaft boot, identify the type of constant velocity joint used and refer to the appropriate procedures for each joint. Separate service procedures are provided for type 1 and 2 constant velocity outer joints and the type 3 and 4 constant velocity inner joints.
1. Raise and support vehicle.
2. Remove front wheel and brake caliper assembly. Secure caliper to the body or spring. Do not allow the brake line to support the weight of the caliper assembly.
3. Using hub locking bar Rou.604.01 or equivalent to secure hub in position, remove driveshaft attaching nut.
4. Using pin drifts, B.Vi.31.01 or equivalent, remove double roller pins attaching driveshaft to the side gear shaft.
5. Using ball joint extractor T.Av.476 or equivalent, disconnect tie rod end.
6. Remove upper bolt attaching steering knuckle to shock absorber. Loosen but do not remove lower attaching bolt.
7. Tilt brake rotor/steering knuckle assembly outward. The driveshaft splines are secured to the hub splines with Loctite. Use hub puller T.Av.1050 only to break the shaft loose from the hub for removal. Do not attempt to loosen the shaft with a hammer.
8. Remove driveshaft as follows:
a. Position tool T.Av.1050 (only) onto the rotor and hub assembly.
b. Tighten tool attaching bolt to break the driveshaft splines loose from the hub.
c. Disconnect the shaft at the transaxle and carefully remove the shaft from the vehicle. Do not damage the driveshaft boot during removal.

Fig. 4 Driveshaft Identification:

IDENTIFICATION & INSTALLATION

Clean driveshaft and hub splines thoroughly using a wire brush. Lubricate seals and splines on the transaxle side gear shaft and driveshaft with clean chassis grease only. Inspect the driveshaft boot. Replace boot if damaged. Before connecting the driveshaft to the transaxle side gear shaft, identify the type of side gear shaft in the transaxle. Three different types are used as described previously.
Type 1 shafts have a shoulder (C), that is 0.039 inch (1 mm) long. A 0.118 inch (3 mm) thick rubber washer (D) is used between the end of the side gear shaft and driveshaft.
Type 2 shafts have a shoulder (C), that is 0.118 inch (3 mm) long. A 0.197 inch thick rubber washer (D) is used between the ends of the side gear shaft and driveshaft.
Type 3 shafts do not have a machined shoulder and do not require a rubber washer.
Verify the type of side gear shaft and install the appropriate thickness rubber washer (or no washer in type 3 shafts), before installing.
All of the side gear shaft types have a chamfer (E), machined into one side of the roll pin hole. The chamfer is included to make installation of the double roller pins easier.

Fig. 5 Aligning Roll Pin Holes In Driveshaft Side Gear:

To install, proceed as follows:
1. Install driveshaft (F), onto side gear shaft (G).
2. Align roll pin holes (H) in the driveshaft (F) side gear (G).
3. Install driveshaft onto side gear shaft and insert double roll pins (one pin fits inside the other). Position slits into pins 180° apart. Tap pins (J) into place with pin drifts B.Vi.31.01 or equivalent.
4. Seal open ends of the roll pins with silicone sealer after installation.
5. Apply a few drops of Loctite 271 to the driveshaft splines and insert shaft into hub assembly. Use installer tool T.Av.602 of the shafts are difficult to install into hub. Do not damage the driveshaft boot while installing the shaft.
6. Apply Loctite 271 onto driveshaft nut and install nut. Using hub locking bar Rou.604.01 or equivalent, tighten nut to 185 ft. lbs.
7. Connect tie rod end to shock arm.
8. Install brake caliper, wheel and lower vehicle.
9. Apply brakes several times to seat pads before moving vehicle.