Intermediate Axle Shaft Removal

REMOVAL





1. Disconnect negative battery cable terminal from battery.
2. Remove right drive axle (refer to "Drive Axle Removal" procedure).





3. On vehicles equipped with DOHC (LL0) engine:
a. Loosen, but do not remove top fastener of intake manifold-to-intermediate axle shaft support bracket.
b. Remove lower fastener of intake manifold-to-intermediate axle shaft support bracket.
c. Swing intermediate manifold-to-intermediate axle shaft support bracket to provide clearance.
d. Tighten fastener at intake manifold to hold bracket aside.





4. Remove intermediate axle drive shaft support bracket-to-engine block fasteners.
5. Remove intermediate drive assembly from vehicle.

DISASSEMBLY

NOTICE: Use soft metal or wood in between vice jaws to protect the shaft.





1. Clamp the drive axle shaft in a vice.





2. If drive axle has a damaged deflector ring, remove the ring from the CV outer race with a brass drift and hammer, as shown, and discard. (Non ABS shown.)
3. Remove outer CV joint and joint boot.





a. Use a hammer and chisel or a flat blade screw driver to disengage outer band from inner band at retainer peg on both large and small boot clamps and discard clamps.
b. Separate joint boot from CV joint race at large diameter and slide boot away from joint along axle shaft.
c. Wipe excess grease from face of CV inner race.





d. Spread ends on race retaining ring with C/V Joint Snap Ring Pliers SA9198C (or equivalent), and remove CV joint assembly from axle shaft.
e. Remove boot from axle shaft.





4. If drive axle is equipped with a dynamic damper, and damper or axle shaft is being replaced, remove damper using an arbor press.
5. Disassemble CV joint.





a. Using a brass drift, gently tap on 6) cage until tilted enough to remove first ball.
b. Remove remaining balls in similar manner.
c. With all balls removed, pivot cage and inner race at 90 degrees to center line of A) outer race with cage windows aligned with lands of outer race, lift out cage and inner race.
d. Rotate inner race up and out of cage. Thoroughly degrease all CV joint parts and allow to dry prior to assembly.
6. Assemble CV joint.
a. Inspect parts for unusual wear, cracks and other damage. Replace joint assembly if needed.
b. Put a light coat of recommended grease on inner and outer race grooves. Insert and rotate inner race into cage.
d. Install cage and inner race into outer race with windows of cage aligned with lines of outer race.
e. Install balls using a brass drift to gently rotate and position cage and inner race.
f. If removed, install race retaining ring into inner race.
g. Pack assembled joint with grease provided in service kit. (The amount of grease supplied with service kits has been pre-measured for each application.)
7. Remove tri-pot joint and joint boot.





a. Cut eared boot retaining clamp on tri-pot boot with side cutters and discard.
b. Remove earless clamp, using a small-blade screwdriver and discard.





c. Separate boot from tri-pot housing at large diameter and slide boot away from joint along axle shaft.
d. Wipe excess grease from face of tri-pot spider and inside of tri-pot housing.
e. Remove tri-pot housing from the spider and shaft.





f. Spread (1) spacer ring with CIV Joint Snap Ring Pliers SA9198C (or equivalent) and slide spacer ring and tri-pot spider back on axle as shown.

NOTICE: Handle the tri-pot spider assembly with care. Tri-pot balls and needle rollers may separate from spider trunnions.

g. Remove (2) spider retaining ring from groove on axle shaft and slide spider assembly off of shaft.
h. Remove boot from axle shaft.
i. Thoroughly degrease the housing and allow to dry prior to assembly.

ASSEMBLY

- TOOLS REQUIRED
- SA9203C Axle Clamp Installer
- SA9198C CV Joint Snap Ring Pliers
- SA9160C Axle Deflector Ring Installer
- SA9161C Axle Boot Clamp Installer
- SA9164C Steering Gear Clamp Installer

1. Install tri-pot joint and boot.





a. Inspect tri-pot joint components for unusual wear, cracks, and other damage. Replace damaged components as needed.
b. Clean the shaft. If rust is present in the boot mounting area (grooves), wire brush this area.
c. Install small boot retaining clamp on neck of boot. Do not crimp.
d. Slide boot onto shaft and locate neck of boot in proper position in boot groove on axle shaft.
e. Crimp boot retaining clamp with Axle Clamp Installer SA9203C (or equivalent) as shown.

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

f. Measure clamp end gap, and repeat step e if necessary.





g. Install spacer ring on axle shaft and beyond second groove as shown.
h. Slide tri-pot spider assembly past spider (1) retaining ring groove.

NOTICE: Be sure that counterbored surface of tri-pot spider faces end of shaft after installation.

i. Install spider retaining ring in groove of axle shaft with C/V Joint Snap Ring Pliers SA9198C (or equivalent).





j. Slide tri-pot spider towards end of shaft and reseat spacer ring in groove on axle.
k. Place approximately half of the grease (provided in kit) inside boot and use the remainder to repack tri-pot housing.
l. Install convolute retainer (supplied with service kit) over boot.

IMPORTANT: Joint must be assembled with convolute retainer in position. Boot damage will result if joint is not assembled to correct dimension.

m. Position boot retaining clamp around large diameter of boot.
n. Slide tri-pot housing over tri-pot spider assembly on shaft.
o. Slide large diameter of boot over outside of tri-pot housing and locate lip of boot in housing groove.

NOTICE: Boot must not be dimpled, stretched, or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and housing to equalize pressure. Shape boot properly by hand and remove tool.





p. Position tri-pot assembly at proper vehicle dimension as shown.





q. Place large boot retaining clamp around boot and close with Axle Boot Clamp Installer SA9161C (or equivalent).
2. If dynamic damper is being replaced or installed:
a. Thoroughly clean and degrease the drive shaft.

IMPORTANT: Drive shaft must be clean and free of grease to ensure the damper is secure to the drive shaft after installation.





b. Measure 202 mm (7.95 inch) from the outboard end of the drive shaft for location of where damper will be installed. Mark this location with a piece of masking tape.





IMPORTANT: Lubricate shaft with a liquid detergent (example, liquid dishwashing detergent) to aid in damper installation.

c. Place drive shaft in a vice with brass jaws and start damper onto the drive shaft by hand.
d. Work damper onto drive shaft by twisting it back and forth. Align inboard edge of damper with installed masking tape.

IMPORTANT: If more than moderate pressure is required to move the damper, not enough liquid detergent has been applied.

e. Remove masking tape.
f. Secure damper in place by crimping retaining clamp with Axle Boot Clamp Installer SA9164C.
3. Install outer CV joint and boot.





a. Install small retaining clamp on neck of new boot. Do not crimp.
b. Slide boot onto axle shaft and locate neck of boot in proper position in boot groove on axle shaft.
c. Crimp boot retaining clamp with Axle Clamp Installer SA9203C (or equivalent).

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

d. Measure clamp end gap dimension and repeat step C if necessary.
e. Place approximately half of grease (provided in kit) inside boot and repack CV with remaining grease.





f. Position large boot retaining clamp around boot.

NOTICE: Be sure that retaining ring side of inner race faces axle shaft prior to installation.

g. Push CV joint onto axle shaft until retaining ring is seated in groove on axle shaft.





h. Slide large diameter of boot over outside of CV joint race and locate lip of boot in housing groove.

NOTICE: Boot must not be dimpled, stretched or out of shape in any way. If boot is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between large boot opening and outer race to equalize pressure. Shape boot properly by hand and remove tool.

i. Crimp retaining clamp with Axle Clamp Installer SA9203C (or equivalent).

IMPORTANT: Check clamp location during crimp operation to make sure it is positioned correctly around entire circumference.

j. Measure clamp end gap dimension and repeat step if necessary. Dimension should not exceed 2.6 mm (.102 inch)





k. If removed, position deflecting ring at CV joint outer race.
l. Using Axle Deflector Ring Installer SA9160C (or equivalent) and a M20 x 1.5 nut, tighten nut until deflector bottoms against shoulder of CV outer race.