Axle Shaft Assembly: Service and Repair

FRONT DRIVE AXLE SERVICE

Care must be exercised to prevent over extending the tri-pot joints. When either end of the drive axle is disconnected, over extension of the joint may result in separation of the internal components and possible joint failure. Drive axle joint seal protectors should be used any time service is performed.

REMOVAL
1. Raise and support vehicle, then remove front tire and wheel assembly.
2. Insert drift or screwdriver into caliper and rotor to prevent rotor from turning, then remove shaft nut and washer. Discard nut.
3. Remove caliper from steering knuckle and suspend caliper with wire, then remove brake rotor from hub and bearing assembly.
4. Remove lower ball joint and steering knuckle nut.

Fig. 2 Seal Protector Modification.:

5. Install seal protector tool No. J-34754, or equivalent. Seal protector should be modified as shown and installed on any dive axle prior to service procedures on or near drive axle. Failure to do so may result an seal damage and possible joint failure.
6. Remove ball joint from steering knuckle.
7. Remove drive axle from hub and bearing using front hub spindle remover tool No. J- 28733-A, or equivalent, then remove drive axle from transaxle using axle shaft remover tool No. J-33008, or equivalent, with suitable slide hammer and extension.

INSTALLATION
1. Carefully guide axle shaft splines past lip seal. Do not allow shaft splines to contact any part of seal surface, as seal damage will occur.
2. Install axle to transaxle, then axle shaft to hub.
3. Install lower control arm ball joint to steering knuckle, then torque steering knuckle nut to 56 lb ft
4. Install brake rotor, then the caliper.
5. Insert drift or screwdriver to caliper, then install drive axle washer and nut. Torque nut to 180-185 lb ft
6. Remove drift or screwdriver from caliper and rotor, then seat drive axle into transaxle by placing a screwdriver into groove on joint housing and tapping until seated.
7. Pull outward on tri-pot housing to ensure drive axle is fully seated into transaxle. Do not pull on axle shaft.
8. Install wheel and tire assembly, then lower vehicle.