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DIFFERENTIAL AND DRIVELINE

TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
FRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS. . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION . . . . . . . . . . . . . . . . 7
INNER TRIPOD J OINT SEAL BOOT . . . . . . . . . . . 7
OUTER C/V J OINT SEAL BOOT . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIAL TOOLS
DRIVESHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION AND OPERATION
FRONT DRIVESHAFTS
Vehi cl es equi pped wi th ei ther an automati c or
manual transmi ssi on use an unequal –l ength dri ve-
shaft system.
The system i ncorporates two dri veshaft assembl i es
(l eft and ri ght) that consi st of an i nner and outer
constant vel oci ty (CV) joi nt and a sol i d i nterconnect-
i ng shaft (Fi g. 1). The ri ght dri veshaft i s l onger than
the l eft due to transaxl e packagi ng and powertrai n
desi gn.
Fig. 1 Unequal Length Driveshaft System
1 – STUB AXLE
2 – OUTER C/V JOINT
3 – OUTER C/V JOINT BOOT
4 – TUNED RUBBER DAMPER WEIGHT
5 – INTERCONNECTING SHAFT
6 – OUTER C/V JOINT BOOT
7 – STUB AXLE
8 – OUTER C/V JOINT
9 – RIGHT DRIVESHAFT
10 – INNER TRIPOD JOINT BOOT
11 – INNER TRIPOD JOINT
12 – INNER TRIPOD JOINT
13 – INNER TRIPOD JOINT BOOT
14 – INTERCONNECTING SHAFT LEFT DRIVESHAFT
PL DIFFERENTIAL AND DRIVELINE 3 - 1
Dri veshafts used on both the ri ght and l eft si des of
the vehi cl e use a tuned rubber damper wei ght
mounted to the i nterconnecti ng shaft (Fi g. 1). The
damper wei ght appl i cati ons vary by whi ch si de of the
vehi cl e the dri veshaft i s l ocated on and the transmi s-
si on appl i cati on of the vehi cl e. When repl aci ng a
dri veshaft, be sure the repl acement dri veshaft has
the same damper wei ght as the ori gi nal .
Both dri veshaft assembl i es use the same type of
i nner and outer joi nts. The i nner joi nt of both dri ve-
shaft assembl i es i s a tri pod joi nt, and the outer joi nt
of both dri veshaft assembl i es i s a Rzeppa joi nt. Both
tri pod joi nts and Rzeppa joi nts are true constant
vel oci ty (C/V) joi nt assembl i es. The i nner tri pod joi nt
al l ows for the changes i n dri veshaft l ength through
the jounce and rebound travel of the front suspen-
si on.
On vehi cl es equi pped wi th ABS brakes, the outer
C/V joi nt i s equi pped wi th a tone wheel used to
determi ne vehi cl e speed for ABS brake operati on.
The i nner tri pod joi nt of both dri veshafts i s spl i ned
i nto the transaxl e si de gears. The i nner tri pod joi nts
are retai ned i n the si de gears of the transaxl e usi ng
a snap ri ng l ocated i n the stub shaft of the tri pod
joi nt. The outer C/V joi nt has a stub shaft that i s
spl i ned i nto the wheel hub and retai ned by a si ngl e
pi ece steel hub nut (Fi g. 2). The hub nut i s a l ocki ng
styl e; the nut l ock, anti -rattl e washer, and cotter pi n
are not necessary.
NOTE: This vehicle does not use a rubber–lip bear-
ing seal as on previous front–wheel–drive cars to
prevent contamination of the front wheel bearing.
On these vehicles, the face of the outer C/V joint
fits deeply into the steering knuckle, using a close
outer C/V joint–to–steering knuckle fit. This design
deters direct water splash on bearing seal while
allowing any water that gets in, to run out the bot-
tom of the steering knuckle bearing bore. It is
important to thoroughly clean the outer C/V joint
and the wheel bearing area in the steering knuckle
before it is assembled after servicing.
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS
VEHICLE INSPECTION
(1) Check for grease i n the vi ci ni ty of the i nboard
tri pod joi nt and outboard C/V joi nt; thi s i s a si gn of
i nner or outer joi nt seal boot or seal boot cl amp dam-
age.
(2) A l i ght fi l m of grease may appear on the ri ght
i nner tri pod joi nt seal boot; thi s i s consi dered normal
and shoul d not requi re repl acement of the seal boot.
The ri ght i nner tri pod joi nt seal boot i s made of si l i -
cone rubber; whi ch wi l l al l ow the weepi ng (sweati ng)
of the joi nt l ubri cant to pass through i t whi l e i n oper-
ati on.
NOISE AND/OR VIBRATION IN TURNS
A cl i cki ng noi se and/or a vi brati on i n turns coul d
be caused by one of the fol l owi ng condi ti ons.
(1) Damaged outer C/V or i nner tri pod joi nt seal
boot or seal boot cl amps. Thi s wi l l resul t i n the l oss
and/or contami nati on of the joi nt grease, resul ti ng i n
i nadequate l ubri cati on of the joi nt.
(2) Noi se may al so be caused by another compo-
nent of the vehi cl e comi ng i n contact wi th the dri ve-
shafts.
CLUNKING NOISE DURING ACCELERATION
Thi s noi se may be a resul t of one of the fol l owi ng
condi ti ons:
(1) A torn seal boot on the i nner or outer joi nt of
the dri veshaft assembl y.
(2) A l oose or mi ssi ng cl amp on the i nner or outer
joi nt of the dri veshaft assembl y.
(3) A damaged or worn dri veshaft C/V joi nt.
Fig. 2 Driveshaft Retaining Nut
1 – DRIVESHAFT
2 – HUB
3 – HUB NUT
3 - 2 DIFFERENTIAL AND DRIVELINE PL
DESCRIPTION AND OPERATION (Continued)
SHUDDER OR VIBRATION DURING ACCELERATION
(1) A worn or damaged dri veshaft i nner tri pod
joi nt.
(2) A sti cki ng tri pod joi nt spi der assembl y (i nner
tri pod joi nt onl y).
(3) I mproper wheel al i gnment. See Wheel Al i gn-
ment i n thi s group for al i gnment checki ng and set-
ti ng procedures and speci fi cati ons.
VIBRATION AT HIGHWAY SPEEDS
(1) Forei gn materi al (mud, etc.) packed on the
backsi de of the wheel (s).
(2) Out of bal ance front ti res or wheel s. See Group
22, Wheel s And Ti res for the requi red bal anci ng pro-
cedure.
(3) I mproper ti re and/or wheel runout. See Group
22, Wheel s And Ti res for the requi red runout check-
i ng procedure.
REMOVAL AND INSTALLATION
DRIVESHAFTS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the driveshaft
to prevent damage.
REMOVAL
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N·m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(1) Di sconnect battery negati ve cabl e.
(2) Pl ace transaxl e i n gated park.
(3) Rai se vehi cl e on hoi st.
(4) Remove wheel and ti re assembl y (Fi g. 3).
(5) Remove the dri veshaft to hub and beari ng
retai ni ng nut (Fi g. 4).
(6) I f equi pped wi th ABS, di sconnect the front
wheel speed sensor and secure harness out of the
way.
Fig. 3 Wheel and Tire Removal
1 – WHEEL/TIRE ASSY.
2 – LUG NUT (5)
3 – HUB
Fig. 4 Driveshaft Retaining Nut Removal
1 – DRIVESHAFT
2 – HUB
3 – HUB NUT
PL DIFFERENTIAL AND DRIVELINE 3 - 3
DIAGNOSIS AND TESTING (Continued)
(7) Remove nut and bol t (Fi g. 5) retai ni ng bal l
joi nt stud i nto steeri ng knuckl e.
NOTE: Use caution when separating ball joint stud
from steering knuckle, so ball joint seal does not
get damaged.
(8) Separate bal l joi nt stud from steeri ng knuckl e
by pryi ng down on l ower control arm (Fi g. 6).
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.
(9) Remove dri veshaft from steeri ng knuckl e by
pul l i ng outward on knuckl e whi l e pressi ng i n on
dri veshaft. Support outer end of dri veshaft assembl y.
I f di ffi cul ty i n separati ng dri veshaft from steeri ng
knuckl e i s encountered, perform the fol l owi ng proce-
dure:
(a) I nstal l Pul l er, Speci al Tool 6790 on hub and
beari ng assembl y (Fi g. 7), usi ng wheel l ug nuts to
secure i t i n pl ace.
(b) I nstal l a wheel l ug nut on wheel stud to pro-
tect the threads on the stud. I nstal l a fl at bl ade
pry tool to keep hub from turni ng. Usi ng Pul l er,
force the dri veshaft outer stub axl e from the hub
and beari ng assembl y (Fi g. 8).
(c) Pul l steeri ng knuckl e assembl y out and away
from outer C/V joi nt of the dri veshaft assembl y as
shown i n (Fi g. 5).
(10) Support outer end of the dri veshaft assembl y.
NOTE: Removal of the inner tripod joints is made
easier if you apply outward pressure on the joint as
you strike the punch with a hammer.
Fig. 5 Steering Knuckle at Lower Control Arm Ball
Joint
1 – NUT
2 – BOLT
3 – BALL JOINT
Fig. 6 Separating Lower Control Arm from Steering
Knuckle
1 – STEERING KNUCKLE
2 – PRY BAR
3 – LOWER CONTROL ARM
4 – BALL JOINT STUD
Fig. 7 Puller Installed On Hub/Bearing Assembly
1 – TOOL 6790
3 - 4 DIFFERENTIAL AND DRIVELINE PL
REMOVAL AND INSTALLATION (Continued)
(11) Remove the i nner tri pod joi nts from the si de
gears of the transaxl e usi ng a punch to di sl odge the
i nner tri pod joi nt retai ni ng ri ng from the transaxl e
si de gear. I f removi ng the ri ght si de i nner tri pod
joi nt, posi ti on the punch agai nst the i nner tri pod
joi nt (Fi g. 9). Stri ke the punch sharpl y wi th a ham-
mer to di sl odge the ri ght i nner joi nt from the si de
gear. I f removi ng the l eft si de i nner tri pod joi nt, posi -
ti on the punch i n the groove of the i nner tri pod joi nt
(Fi g. 10). Stri ke the punch sharpl y wi th a hammer to
di sl odge the l eft i nner tri pod joi nt from the si de gear.
(12) Hol d i nner tri pod joi nt and i nterconnecti ng
shaft of dri veshaft assembl y (Fi g. 11). Remove i nner
tri pod joi nt from transaxl e by pul l i ng i t strai ght out
of transaxl e si de gear and transaxl e oi l seal . When
removing tripod joint, do not let spline or snap
ring drag across sealing lip of the transaxle to
tripod joint oil seal. When tripod joint is
removed from transaxle, some fluid will leak
out.
Fig. 8 Removing Stub Axle From Hub/Bearing
1 – TOOL 6790
Fig. 9 Disengaging Right Inner Tripod Joint from
Transaxle
1 – TRANSAXLE
2 – RIGHT INNER TRIPOD JOINT
3 – PUNCH
Fig. 10 Disengaging Left Inner Tripod Joint from
Transaxle
1 – FRONT SUSPENSION CROSSMEMBER
2 – DRIFT
3 – TRANSAXLE
4 – DRIVESHAFT INNER TRIPOD JOINT
5 – NOTCH
Fig. 11 Tripod Joint Removal from Transaxle
1 – INNER TRIPOD JOINT
2 – TRANSAXLE
3 – SPLINE
4 – OIL SEAL
5 – SNAP RING
6 – INTERCONNECTING SHAFT
PL DIFFERENTIAL AND DRIVELINE 3 - 5
REMOVAL AND INSTALLATION (Continued)
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N·m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
INSTALLATION
(1) Thoroughl y cl ean spl i ne and oi l seal seal i ng
surface, on tri pod joi nt. Li ghtl y l ubri cate oi l seal
seal i ng surface on tri pod joi nt wi th fresh cl ean trans-
mi ssi on l ubri cant.
(2) Hol di ng dri veshaft assembl y by tri pod joi nt and
i nterconnecti ng shaft, i nstal l tri pod joi nt i nto tran-
saxl e si de gear as far as possi bl e by hand.
(3) Careful l y al i gn tri pod joi nt wi th transaxl e si de
gears. Then grasp dri veshaft i nterconnecti ng shaft
and push tri pod joi nt i nto transaxl e si de gear unti l
ful l y seated. Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.
(4) Cl ean al l debri s and moi sture out of steeri ng
knuckl e (Fi g. 12).
(5) Ensure that front of outer C/V joi nt, whi ch fi ts
i nto steeri ng knuckl e (Fi g. 13), i s free of debri s and
moi sture before assembl i ng i nto steeri ng knuckl e.
(6) Sl i de dri veshaft back i nto front hub. I nstal l
steeri ng knuckl e onto the bal l joi nt stud (Fi g. 14).
NOTE: At this point, the outer joint will not seat
completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.
(7) I nstal l a NEW steeri ng knuckl e to bal l joi nt
stud bol t and nut (Fi g. 14). Ti ghten the nut and bol t
to 95 N·m (70 ft. l bs.).
Fig. 12 Steering Knuckle to C/V Joint Sealing Area
1 – STEERING KNUCKLE
2 – WHEEL BEARING
3 – FRONT HUB
4 – THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE
OF ALL DEBRIS AND MOISTURE BEFORE INSTALLING
DRIVE SHAFT IN STEERING KNUCKLE
Fig. 13 Outer C/V Joint Inspection
1 – OUTER C/V JOINT
2 – THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
Fig. 14 Driveshaft Installation Into Hub And Steering
Knuckle
1 – NUT
2 – BOLT
3 – BALL JOINT
3 - 6 DIFFERENTIAL AND DRIVELINE PL
REMOVAL AND INSTALLATION (Continued)
(8) Cl ean al l forei gn matter from threads of dri ve-
shaft outer stub axl e. I nstal l hub nut onto the
threads of the stub axl e and ti ghten nut to 244 N·m
(180 ft. l bs.) (Fi g. 15).
(9) I nstal l front wheel and ti re assembl y. I nstal l
front wheel l ug nuts (Fi g. 16) and ti ghten to 128 N·m
(95 ft. l bs.).
(10) Check for correct fl ui d l evel i n transaxl e
assembl y. Refer to Group 21 Transaxl e, for the cor-
rect fl ui d l evel checki ng procedure for the type of
transaxl e bei ng checked.
(11) Lower vehi cl e.
(12) Connect battery negati ve cabl e.
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION
NOTE: The only service that is to be performed on
the driveshaft assemblies is the replacement of the
driveshaft seal boots.
I f any fai l ure of i nternal dri veshaft components i s
di agnosed duri ng a vehi cl e road test or di sassembl y
of the dri veshaft, the dri veshaft wi l l need to be
repl aced as an assembl y.
NOTE: Lubricant requirements and quantities are
different for inner joints than for outer joints. Use
only the recommended lubricants in the required
quantities when servicing driveshaft assemblies.
See (Fi g. 17) for the expl oded vi ew of the front
dri veshaft components.
INNER TRIPOD JOINT SEAL BOOT
REMOVAL
To remove seal i ng boot from dri veshaft for repl ace-
ment, the dri veshaft assembl y must be removed from
the vehi cl e. See Dri veshaft Removal and I nstal l ati on
i n thi s secti on for the requi red dri veshaft removal
and repl acement procedure.
The i nner tri pod joi nts use no i nternal retenti on i n
the tri pod housi ng to keep the spi der assembl y i n the
housi ng. Therefore, do not pul l on the i nterconnect-
i ng shaft to di sengage tri pod housi ng from transmi s-
si on stub shaft. Removal i n thi s manner wi l l cause
damage to the i nboard joi nt seal i ng boots.
(1) Remove the dri veshaft requi ri ng boot repl ace-
ment from the vehi cl e. See Dri veshaft Removal and
I nstal l ati on i n thi s secti on for the requi red dri veshaft
removal procedure.
(2) Remove l arge boot cl amp that retai ns i nner tri -
pod joi nt seal i ng boot to tri pod joi nt housi ng (Fi g. 18)
and di scard. Then remove smal l cl amp that retai ns
i nner tri pod joi nt seal i ng boot to i nterconnecti ng
shaft and di scard. Remove the seal i ng boot from the
tri pod housi ng and sl i de i t down the i nterconnecti ng
shaft.
Fig. 15 Driveshaft Retaining Nut Installation
1 – DRIVESHAFT
2 – HUB
3 – HUB NUT
Fig. 16 Wheel and Tire Installation
1 – WHEEL/TIRE ASSY.
2 – LUG NUT (5)
3 – HUB
PL DIFFERENTIAL AND DRIVELINE 3 - 7
REMOVAL AND INSTALLATION (Continued)
Fig. 17 Driveshaft Assembly Components (Exploded View)
1 – HOUSING ASM, RETAINER &
2 – RING, SPACER
3 – SPIDER, TRIPOTD JOINT
4 – RING, RETAINING
5 – RETAINER, BALL & ROLLER
6 – BALL, TRIPOD JOINT
7 – ROLLER, NEEDLE
8 – CLAMP, SEAL RETAINING
9 – BUSHING, TRILOBAL TRIPOD
10 – SEAL, DRIVE AXLE INBOARD
11 – CLAMP, SEAL RETAINING
12 – SHAFT, AXLE (RH SHOWN, LH SIMILAR)
13 – SEAL, DRIVE AXLE OUTBOARD
14 – CLAMP, SEAL RETAINING
15 – RING, RACE RETAINING
16 – BALL, CHROME ALLOY
17 – RACE, C/V JOINT INNER
18 – CAGE, C/V JOINT
19 – RACE, C/V JOINT OUTER
3 - 8 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: When removing the spider joint from the
tripod joint housing, hold the rollers in place on the
spider trunions to prevent the rollers and needle
bearings from falling away.
(3) Sl i de the i nterconnecti ng shaft and spi der
assembl y out of the tri pod joi nt housi ng (Fi g. 19).
(4) Remove snap ri ng that retai ns spi der assembl y
to i nterconnecti ng shaft (Fi g. 20). Remove the spi der
assembl y from i nterconnecti ng shaft. I f spi der assem-
bl y wi l l not come off i nterconnecti ng shaft by hand, i t
can be removed by tappi ng spi der assembl y wi th a
brass dri ft (Fi g. 21). Do not hit the outer tripod
bearings in an attempt to remove spider assem-
bly from interconnecting shaft.
(5) Sl i de seal i ng boot off i nterconnecti ng shaft.
(6) Thoroughl y cl ean and i nspect spi der assembl y,
tri pod joi nt housi ng, and i nterconnecti ng shaft for
any si gns of excessi ve wear. If any parts show
signs of excessive wear, the driveshaft assembly
will require replacement. Component parts of
these driveshaft assemblies are not serviceable.
Fig. 18 Inner Tripod Joint Sealing Boot Clamps
1 – SMALL CLAMP
2 – LARGE CLAMP
3 – INNER TRIPOD JOINT
4 – SEALING BOOT
5 – INTERCONNECTING SHAFT
Fig. 19 Spider Assembly Joint Removal from
Housing
1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT
Fig. 20 Spider Assembly Retaining Snap Ring
1 – INTERCONNECTING SHAFT
2 – SPIDER ASSEMBLY
3 – RETAINING SNAP RING
Fig. 21 Spider Assembly Removal from
Interconnecting Shaft
1 – SPIDER ASSEMBLY
2 – DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN
REMOVING SPIDER ASSEMBLY
3 – BRASS DRIFT
4 – INTERCONNECTING SHAFT
PL DIFFERENTIAL AND DRIVELINE 3 - 9
DISASSEMBLY AND ASSEMBLY (Continued)
INSTALLATION
NOTE: The inner tripod joint sealing boots are
made from two different types of material. High–
temperature applications use silicone rubber
whereas standard temperature applications use
Hytrel plastic. The silicone sealing boots are soft
and pliable. The Hytrel sealing boots are stiff and
rigid. The replacement sealing boot MUST BE the
same type of material as the sealing boot that was
removed.
(1) Sl i de i nner tri pod joi nt seal boot retai ni ng
cl amp, onto i nterconnecti ng shaft. Then sl i de the
repl acement i nner tri pod joi nt seal i ng boot onto
i nterconnecti ng shaft. Inner tripod joint seal boot
MUST be positioned on interconnecting shaft,
so the raised bead on the inside of the seal boot
is in groove on interconnecting shaft (Fig. 22).
(2) I nstal l spi der assembl y onto i nterconnecti ng
shaft wi th chamfer on spi der assembl y toward i nter-
connecti ng shaft (Fi g. 23). Spi der assembl y must be
i nstal l ed on i nterconnecti ng shaft far enough to ful l y
i nstal l spi der retai ni ng snap ri ng. I f spi der assembl y
wi l l not ful l y i nstal l on i nterconnecti ng shaft by
hand, i t can be i nstal l ed by tappi ng the spi der body
wi th a brass dri ft (Fi g. 24). Do not hit the outer
tripod bearings in an attempt to install spider
assembly on interconnecting shaft.
(3) I nstal l the spi der assembl y to i nterconnecti ng
shaft retai ni ng snap ri ng i nto groove on end of i nter-
connecti ng shaft (Fi g. 25). Be sure the snap ri ng i s
ful l y seated i nto groove on i nterconnecti ng shaft.
(4) Di stri bute 1/2 the amount of grease provi ded i n
the seal boot servi ce package (DO NOT USE ANY
OTHER TYPE OF GREASE) i nto tri pod housi ng. Put
the remai ni ng amount i nto the seal i ng boot.
(5) Al i gn tri pod housi ng wi th spi der assembl y and
then sl i de tri pod housi ng over spi der assembl y and
i nterconnecti ng shaft (Fi g. 26).
(6) I nstal l i nner tri pod joi nt seal boot to i ntercon-
necti ng shaft cl amp evenl y on seal i ng boot.
Fig. 22 Sealing Boot Installation on Interconnecting
Shaft
1 – SEALING BOOT
2 – RAISED BEAD IN THIS AREA OF SEALING BOOT
3 – GROOVE
4 – INTERCONNECTING SHAFT
Fig. 23 Spider Assembly Installation on
Interconnecting Shaft
1 – SPIDER ASSEMBLY
2 – INTERCONNECTING SHAFT
3 – CHAMFER
Fig. 24 Installing Spider Assembly On
Interconnecting Shaft
1 – DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER
ASSEMBLY
2 – SPIDER ASSEMBLY
3 – INTERCONNECTING SHAFT
4 – BRASS DRIFT
3 - 10 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Cl amp seal i ng boot onto i nterconnecti ng shaft
usi ng cri mper, Speci al Tool C-4975-A and the fol l ow-
i ng procedure. Pl ace cri mpi ng tool C-4975-A over
bri dge of cl amp (Fi g. 27). Ti ghten nut on cri mpi ng
tool C-4975-A unti l jaws on tool are cl osed compl etel y
together, face to face (Fi g. 28).
CAUTION: Seal must not be dimpled, stretched, or
out–of–shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Posi ti on seal i ng boot i nto the tri pod housi ng
retai ni ng groove. I nstal l seal boot retai ni ng cl amp
evenl y on seal i ng boot.
CAUTION: The following positioning procedure
determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing
boot to inner tripod joint housing. If this procedure
is not done prior to clamping sealing boot to tripod
joint housing, boot durability can be adversely
affected.
Fig. 25 Spider Assembly Retaining Snap Ring
Installed
1 – INTERCONNECTING SHAFT
2 – SPIDER ASSEMBLY
3 – RETAINING SNAP RING
Fig. 26 Installing Tripod Housing on Spider
Assembly
1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT
Fig. 27 Crimping Tool Installed on Sealing Boot
Clamp
1 – SPECIAL TOOL C-4975A
2 – INTERCONNECTING SHAFT
3 – CLAMP
4 – SEALING BOOT
Fig. 28 Sealing Boot Retaining Clamp Installed
1 – CLAMP
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 – INTERCONNECTING SHAFT
4 – SEALING BOOT
PL DIFFERENTIAL AND DRIVELINE 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: When venting the inner tripod joint
assembly, use care so inner tripod sealing boot
does not get punctured or, in any other way, dam-
aged. If sealing boot is punctured or damaged while
being vented, the sealing boot can not be used.
(9) I nsert a tri m sti ck between the tri pod joi nt and
the seal i ng boot to vent i nner tri pod joi nt assembl y
(Fi g. 29). When inserting trim stick between tri-
pod housing and sealing boot, ensure trim stick
is held flat and firmly against the tripod hous-
ing. If this is not done, damage to the sealing
boot can occur. I f i nner tri pod joi nt has a Hytrel
(hard pl asti c) seal i ng boot, be sure tri m sti ck i s
i nserted between soft rubber i nsert and tri pod hous-
i ng, and not the hard pl asti c seal i ng boot and soft
rubber i nsert.
(10) Wi th tri m sti ck i nserted between seal i ng boot
and tri pod joi nt housi ng, posi ti on i nner tri pod joi nt
on dri veshaft unti l correct seal i ng boot edge to edge
l ength i s obtai ned for type of seal i ng boot materi al
bei ng used (Fi g. 30) (Fi g. 31). Then remove the tri m
sti ck.
(11) Cl amp tri pod joi nt seal i ng boot to tri pod joi nt
usi ng requi red procedure for type of boot cl amp
appl i cati on. I f seal boot uses cri mp type boot cl amp,
cl amp seal i ng boot onto tri pod housi ng usi ng cri mper,
Speci al Tool C-4975-A. Pl ace cri mpi ng tool C-4975-A
over bri dge of cl amp (Fi g. 32). Ti ghten nut on cri mp-
i ng tool C-4975-A unti l jaws on tool are cl osed com-
pl etel y together, face–to–face (Fi g. 33).
(12) I f seal boot uses l ow profi l e l atchi ng type boot
cl amp, cl amp seal i ng boot onto tri pod housi ng usi ng
cl amp l ocki ng tool , Snap-On௡ YA3050 (or an equi va-
l ent). Pl ace prongs of cl amp l ocki ng tool i n the hol es
of the cl amp (Fi g. 34). Squeeze tool together unti l top
band of cl amp i s l atched behi nd the two tabs on
l ower band of cl amp (Fi g. 35).
Fig. 29 Trim Stick Inserted for Venting Tripod Joint
1 – INNER TRIPOD JOINT SEALING BOOT
2 – SEALING BOOT CLAMP
3 – INNER TRIPOD JOINT HOUSING
4 – TRIM STICK
Fig. 30 Sealing Boot End to End Length with Hytrel
Boot
1 – 107 MILLIMETERS
2 – HYTREL SEALING BOOT
3 – SEALING BOOT CLAMP
4 – INNER TRIPOD JOINT
Fig. 31 Sealing Boot End to End Length with
Silicone Boot
1 – 115 MILLIMETERS
2 – SILICONE SEALING BOOT
3 – CLAMP
4 – INNER TRIPOD JOINT
3 - 12 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
(13) I nstal l the dri veshaft requi ri ng boot repl ace-
ment back on the vehi cl e. See Dri veshaft Removal
and I nstal l ati on i n thi s secti on for the requi red dri ve-
shaft i nstal l ati on procedure.
OUTER C/V JOINT SEAL BOOT
REMOVAL
To remove outer C/V joi nt seal i ng boot from a dri ve-
shaft for repl acement, the dri veshaft assembl y must
be removed from the vehi cl e. See Dri veshaft Removal
and I nstal l ati on i n thi s secti on for the requi red dri ve-
shaft removal and repl acement procedure.
(1) Remove dri veshaft assembl y requi ri ng boot
repl acement from vehi cl e. See Dri veshaft Removal
and I nstal l ati on i n thi s secti on for the requi red dri ve-
shaft removal procedure.
Fig. 32 Crimping Tool Installed on Sealing Boot
Clamp
1 – CLAMP
2 – TRIPOD JOINT HOUSING
3 – SPECIAL TOOL C-4975A
4 – SEALING BOOT
Fig. 33 Sealing Boot Retaining Clamp Installed
1 – CLAMP
2 – TRIPOD HOUSING
3 – SPECIAL TOOL C-4975A
4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 – SEALING BOOT
Fig. 34 Clamping Tool Installed on Sealing Boot
Clamp
1 – CLAMP
2 – SPECIAL TOOL YA3050
3 – SEALING BOOT
Fig. 35 Sealing Boot Clamp Correctly Installed
1 – INNER TRIPOD JOINT HOUSING
2 – TOP BANK OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 – SEALING BOOT
PL DIFFERENTIAL AND DRIVELINE 3 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove l arge boot cl amp retai ni ng C/V joi nt
seal i ng boot to C/V joi nt housi ng (Fi g. 36) and di s-
card. Remove smal l cl amp that retai ns outer C/V
joi nt seal i ng boot to i nterconnecti ng shaft and di s-
card. Remove seal i ng boot from outer C/V joi nt hous-
i ng and sl i de i t down i nterconnecti ng shaft.
(3) Wi pe away grease to expose outer C/V joi nt and
i nterconnecti ng shaft.
(4) Remove outer C/V joi nt from i nterconnecti ng
shaft usi ng the fol l owi ng procedure: Support i nter-
connecti ng shaft i n a vi se equipped with protec-
tive caps on jaws of vise to prevent damage to
interconnecting shaft. Then, usi ng a soft–faced
hammer, sharpl y hi t the end of the C/V joi nt hous-
i ng to di sl odge housi ng from i nternal ci rcl i p on i nter-
connecti ng shaft (Fi g. 37). Then sl i de outer C/V joi nt
off end of i nterconnecti ng shaft, joi nt may have to be
tapped off shaft usi ng a soft–faced hammer.
(5) Remove l arge ci rcl i p (Fi g. 38) from the i nter-
connecti ng shaft before attempti ng to remove outer
C/V joi nt seal i ng boot.
(6) Sl i de fai l ed seal i ng boot off i nterconnecti ng
shaft.
(7) Thoroughl y cl ean and i nspect outer C/V joi nt
assembl y and i nterconnecti ng joi nt for any si gns of
excessi ve wear. If any parts show signs of exces-
sive wear, the driveshaft assembly will require
replacement. Component parts of these drive-
shaft assemblies are not serviceable.
INSTALLATION
(1) Sl i de new seal i ng boot to i nterconnecti ng shaft
retai ni ng cl amp onto i nterconnecti ng shaft. Sl i de the
outer C/V joi nt assembl y seal i ng boot onto the i nter-
connecti ng shaft (Fi g. 39). Seal boot MUST be
positioned on interconnecting shaft so the
raised bead on the inside of the seal boot is in
groove on interconnecting shaft.
(2) Al i gn spl i nes on i nterconnecti ng shaft wi th
spl i nes on cross of outer C/V joi nt assembl y and start
outer C/V joi nt onto i nterconnecti ng shaft.
(3) I nstal l outer C/V joi nt assembl y onto i ntercon-
necti ng shaft by usi ng a soft–faced hammer and
tappi ng end of stub axl e (wi th nut i nstal l ed) unti l
outer C/V joi nt i s ful l y seated on i nterconnecti ng
shaft (Fi g. 40).
Fig. 36 Outer C/V Joint Seal Boot Clamps
1 – SMALL CLAMP
2 – SEALING BOOT
3 – OUTER C/V JOINT HOUSING
4 – LARGE CLAMP
5 – INTERCONNECTING SHAFT
Fig. 37 Outer C/V Joint Removal from
Interconnecting Shaft
1 – SOFT HAMMER (TAP HOUSING)
2 – WEAR SLEEVE
3 – CIRCLIP (OUTER END OF SHAFT)
Fig. 38 Circlip Removal from Interconnecting Shaft
1 – SNAP RING PLIERS
2 – INTERCONNECTING SHAFT
3 – CIRCLIP
3 - 14 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Outer C/V joi nt assembl y must be i nstal l ed on
i nterconnecti ng shaft unti l cross of outer C/V joi nt
assembl y i s seated agai nst ci rcl i p on i nterconnecti ng
shaft (Fi g. 41).
(5) Di stri bute 1/2 the amount of grease provi ded i n
seal boot servi ce package (DO NOT USE ANY
OTHER TYPE OF GREASE) i nto outer C/V joi nt
assembl y housi ng. Put the remai ni ng amount i nto
the seal i ng boot.
(6) I nstal l outer C/V joi nt seal i ng boot to i ntercon-
necti ng shaft cl amp evenl y on seal i ng boot.
(7) Cl amp seal i ng boot onto i nterconnecti ng shaft
usi ng cri mper, Speci al Tool C-4975-A and the fol l ow-
i ng procedure. Pl ace cri mpi ng tool C-4975-A over
bri dge of cl amp (Fi g. 42). Ti ghten nut on cri mpi ng
tool C- 4975-A unti l jaws on tool are cl osed com-
pl etel y together, face to face (Fi g. 43).
Fig. 39 Sealing Boot Installation on Interconnecting
Shaft
1 – SEALING BOOT
2 – RAISED BEAD IN THIS AREA OF SEALING BOOT
3 – GROOVE
4 – INTERCONNECTING SHAFT
Fig. 40 Outer C/V Joint Installation on
Interconnecting Shaft
1 – SOFT FACED HAMMER
2 – STUB AXLE
3 – OUTER C/V JOINT
4 – NUT
Fig. 41 Outer C/V Joint Correctly Installed on
Interconnecting Shaft
1 – INTERCONNECTING SHAFT
2 – CROSS
3 – OUTER C/V JOINT ASSEMBLY
Fig. 42 Crimping Tool Installed on Sealing Boot
Clamp
1 – SPECIAL TOOL C-4975A
2 – INTERCONNECTING SHAFT
3 – CLAMP
4 – SEALING BOOT
PL DIFFERENTIAL AND DRIVELINE 3 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: Seal must not be dimpled, stretched, or
out–of–shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Posi ti on outer C/V joi nt seal i ng boot i nto i ts
retai ni ng groove on outer C/V joi nt housi ng. I nstal l
seal i ng boot to outer C/V joi nt retai ni ng cl amp evenl y
on seal i ng boot.
(9) Cl amp seal i ng boot onto outer C/V joi nt hous-
i ng usi ng Cri mper, Speci al Tool C-4975-A and the fol -
l owi ng procedure. Pl ace cri mpi ng tool C-4975-A over
bri dge of cl amp (Fi g. 44). Ti ghten nut on cri mpi ng
tool C-4975-A unti l jaws on tool are cl osed compl etel y
together, face to face (Fi g. 45).
(10) I nstal l the dri veshaft requi ri ng boot repl ace-
ment back on the vehi cl e. See Dri veshaft Removal
and I nstal l ati on i n thi s secti on for the requi red dri ve-
shaft i nstal l ati on procedure.
Fig. 43 Sealing Boot Retaining Clamp Installed
1 – CLAMP
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 – INTERCONNECTING SHAFT
4 – SEALING BOOT
Fig. 44 Crimping Tool Installed on Sealing Boot
Clamp
1 – CLAMP
2 – TRIPOD JOINT HOUSING
3 – SPECIAL TOOL C-4975A
4 – SEALING BOOT
Fig. 45 Sealing Boot Retaining Clamp Installed
1 – CLAMP
2 – TRIPOD HOUSING
3 – SPECIAL TOOL C-4975A
4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 – SEALING BOOT
3 - 16 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Driveshaft-to-Hub/Bearing
Nut . . . . . . . . . . . . . . . . . . . 244 N·m (180 ft. l bs.)
Knuckle-to-Ball J oint
Bol t/Nut . . . . . . . . . . . . . . . . . 95 N·m (70 ft. l bs.)
Wheel/Tire-to-Hub/Bearing
Lug Nuts . . . . . . . . . . . . . . . 128 N·m (95 ft. l bs.)
SPECIAL TOOLS
DRIVESHAFT
Boot Clamp Installer C-4975A
Puller 6790
PL DIFFERENTIAL AND DRIVELINE 3 - 17