Driveshaft Replacement

1. Remove cotter pin, nut lock and spring washer from stub axle.
2. With brakes applied loosen but do not remove hub nut.

NOTE: Hub and driveshaft are splined together through knuckle and retained by hub nut.

3. Raise and support vehicle, then remove front wheel and tire assembly.
4. Remove front disc brake caliper to steering knuckle mounting bolts.
5. Remove caliper and support with suitable wire hook.

CAUTION: Do not allow caliper to hang by hydraulic hose.

6. Remove brake disc, then the hub nut and washer from stub axle.

Fig. 4 Tie Rod End Nut Removal:

7. Hold tie rod end with 11/32 socket, then remove outer tie rod end to steering knuckle nut with a suitable wrench.

Fig. 5 Tie Rod End Removal:

8. Remove tie rod end from steering knuckle with removal tool No. MB-990635, or equivalent.
9. Remove wheel speed sensor from steering knuckle, then the wheel stop.
10. Remove nut and bolt clamping steering knuckle to ball joint stud.

Fig. 6 Steering Knuckle & Ball Joint Separation:

11. With a suitable pry bar separate steering knuckle from ball joint.

CAUTION: Do not damage ball joint grease seal.

12. Pull knuckle assembly out and away from outer C/V joint of driveshaft.

Fig. 7 Right Side Inner Tripod Joint Removal:

Fig. 8 Left Side Inner Tripod Joint Removal:

13. Insert a suitable pry bar between inner tripod joint and transaxle case, then pry against inner tripod joint until snap ring disengages from transaxle side gear.
14. While holding inner tripod joint and interconnecting shaft, remove driveshaft assembly by pulling straight out from transaxle side gear.

CAUTION: Do not drag spline or snap ring across sealing lip of transaxle to tripod joint oil seal.

15. Reverse procedure to install, noting the following:
a. Thoroughly clean and lubricate spline and oil seal sealing surface on tripod joint with suitable transaxle lubricant.
b. Insert tripod joint into transaxle side gear and push tripod joint in until snap ring engages with side gear.
c. Install a new steering knuckle to ball joint clamping bolt and nut.
d. Tighten hub nut with full vehicle load on axle.