Drive Axle - Revised Replacement

Number: 93-241-4D
Section: 4D
Date: JUNE 1993
Corporate Bulletin No.: 334401
ASE No.: A3

Subject:
DRIVE AXLE REPLACEMENT

Model and Year:
1990-93 GEO STORM

SERVICE UPDATE

The service procedure contained in this bulletin replaces the "Drive Axle" procedure in DRIVE AXLE (SECTION 4D) of the 1990-93 Geo Storm Service Manuals (ST371-90, ST371-91, ST371-92 and ST371-93, respectively). Use this procedure whenever removing or installing drive axles on a Geo Storm.

DRIVE AXLE

Remove or Disconnect

Tools Required:
J 21687-02 Tie Rod End Remover
J 34754 Inner Drive Joint Seal Protector

NOTICE:
Care must be exercised to prevent the differential-side joint from being overextended. When either end of the shaft is disconnected, over-extension of the differential-side joint could result in separation of internal components and possible joint failure. The J 34754 axle shaft seal protectors should always be used when service is performed on or near the drive axles. Failure to observe this precaution can result in interior joint or seal damage and possible joint failure.





NOTICE:
If the vehicle is to be lowered to the ground and moved, the front wheel bearings must be supported with a 14 mm (9/16 inch) bolt, one 44.45 mm (1-3/4 inch) washer, one 50.8 mm (2 inch) washer and a 14 mm (9/16 inch) nut assembled through the drive shaft opening in the wheel hub (Figure 1). Tighten the nut and bolt to 54 N-m (40 lb.ft.).

Raise and suitably support vehicle. Refer to SECTION 0A.
1. Front wheel cover or cap from front wheel.





2. Front tire and wheel assembly. Refer to SECTION 3E. Unstake drive axle nut (Figure 2).
3. Drive axle nut from drive axle shaft.





4. One nut from tie rod end (Figure 3).





5. Tie rod end from steering knuckle using a J21687- 02 (Figure 4).





6. Two bolts, two nuts and separate ball joint and steering knuckle from control arm (Figure 5).
- Install the J 34754 protectors to the differential side and wheel-side joints.
- Place a block of wood between a prybar and the transaxle to prevent transaxle damage.





7. Differential-side joint from transaxle by gently prying the differential-side joint housing away and out of the transaxle (Figure 6).

Install or Connect

1. Wheel-side joint into steering knuckle.
2. Differential-side joint into transaxle. Remove the J 34754 protectors from the differential side and wheel-side joints.
3. Ball joint and steering knuckle to control arm; secure with two bolts and two nuts. Tighten
- Ball joint-to-control arm bolts and nuts to 156 N-m (114 lb.ft.).
4. Tie rod end to steering knuckle; secure with one nut. Tighten
- Tie rod end nut to 54 N-m (40 lb.ft.).
5. Drive axle nut to drive axle shaft. Tighten
- Drive axle nut to 186 N-m (137 lb.ft.).
- Stake drive axle nut.
6. Front tire and wheel assembly. Refer to SECTION 3E.
7. Front wheel cover or cap to wheel. Lower vehicle.
8. Wheel-side joint from steering knuckle and drive axle from vehicle.

Inspect

Toe adjustment; adjust as necessary. Refer to SECTION 3A.