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Axle shafts transfer power from the transaxle to the driving wheels. Axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at each end. Inner CV joint is splined to transaxle. Outer CV joint is splined to hub assembly and secured by spindle shaft nut.
CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced when leakage or cracks are present. Inner CV joint can be repaired without replacing the assembly. Outer CV joint must be replaced as an assembly.
Inner CV joint is a plunging Tripod Joint (TJ), sometimes referred to as a tripod. The plunging action allows axle shaft length to change as suspension moves up and down. Outer CV joint, which is either a Double-Offset Joint (DOJ) or Birfield Joint (BJ), cannot be rebuilt.
FWD AXLE SHAFT
Removal
1. Raise and support vehicle. Remove front wheels. Drain transaxle if removing right or both axle shafts. Draining transaxle is unnecessary if removing left axle shaft only. Spread locking tab on spindle nut and remove nut. Remove damper fork bolt and damper pinch bolt. Remove damper fork.
2. Remove lower ball joint cotter pin, and loosen castle nut half length of ball joint threads. Using a ball joint puller, separate ball joint from front hub. Remove ball joint castle nut. Lower control arm and steering knuckle. Pull steering knuckle outward and remove axle shaft from hub assembly. If necessary, use a plastic hammer to drive axle shaft out of hub.
DO NOT pull on inner CV joint or disassembly may occur. DO NOT damage seals.
3. Using a large screwdriver, carefully pry inner CV joint and shaft assembly about .5" (12.7 mm) out of transaxle, dislodging retaining ring from its groove at end of drive axle. Grip both sides of inner CV joint and remove axle shaft and CV joint from vehicle.
DO NOT attempt to disassemble outer CV joint; it must be replaced as an assembly. On inner CV joint, mark rollers and roller grooves for reassembly reference.
Disassembly
1. Remove axle shaft from vehicle, and place it on work bench. Remove and discard inner CV joint boot clamps. Slide boot toward outer CV joint to access inner CV joint.
2. Index axle shaft, inner CV joint housing and spider roller to ensure reassembly in original positions. Remove housing from spider assembly. Index rollers and spider to ensure reassembly to original locations. Remove rollers from spider.
3. Remove snap ring securing spider to axle shaft, and remove spider. Remove snap ring, and slide boot off axle shaft. Remove outer CV joint boot clamps. Slide boot off axle shaft inner CV joint end. DO NOT attempt to disassemble outer CV joint. Replace outer CV joint as an assembly only.
Reassembly
1. Thoroughly clean and inspect axle shaft for wear. Replace all defective parts. Wrap axle shaft splines using vinyl tape to prevent damage to dynamic damper and CV joint boots.
2. Install outer CV joint boot, dynamic damper and inner CV joint boot. Remove vinyl tape from axle shaft. DO NOT install CV joint boot clamps yet.
3. Install snap ring in groove on axle shaft. Install spider on axle shaft by aligning marks made at disassembly. Install snap ring into groove. Pack outer CV joint boot with specified amount of molybdenum disulfide grease. Lube spider and inside bores of rollers.
4. Ensure rollers are aligned with marks made at disassembly and high side of rollers face outward. Install rollers. Pack inner CV joint and boot with molybdenum disulfide grease. Align housing marks made at disassembly and install housing on spider assembly.
5. Adjust standard length of axle shaft. See figure. Position boots halfway between full compression and full extension and install boot clamps.
WARNING: Always use a NEW retaining ring when installing axle shaft.
6. Position dynamic damper to correct distance from edge of boot. Bend down lock tab of each boot clamp and lightly tap doubled-over portion of boot clamp to reduce clamp height. Install a NEW retaining ring on end of inner CV joint, and install axle shaft.
