Front Wheel Drive Intermediate Shaft Replacement

Front Wheel Drive Intermediate Shaft Replacement

Special Tools
* J 45341 Rear Wheel Drive Shaft Removal Tool
* SA9173G Slide Hammer
* SA91112T Axle Seal Protector

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
3. Disconnect the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (Service and Repair).
4. Disconnect the outer tie rod assembly from the steering knuckle. Do NOT loosen the tie rod adjustment jamb nut. Refer to Steering Linkage Outer Tie Rod Replacement (Service and Repair).
5. Rotate the steering knuckle to access the wheel drive shaft inner joint.
6. Assemble the J 45341 and the SA9173G to the wheel drive shaft inner tripot housing assembly.




7. Using the J 45341 and the SA9173G , separate the wheel drive shaft from the intermediate drive shaft.
8. Reposition and support the wheel drive shaft from the intermediate drive shaft.
9. Inspect the wheel drive shaft-to-intermediate drive shaft seal (1) for excessive wear, damage, and/or contamination and replace if necessary.




10. Disconnect the electrical connector from the vehicle speed sensor.
11. Remove the intermediate drive shaft bracket-to-engine block bolts, and remove the vehicle speed sensor with the bracket.




12. Remove the remaining intermediate shaft bracket bolt (2).
13. Using care to not damage the transaxle output shaft seal (1), remove the intermediate drive shaft assembly.
14. Inspect the front wheel drive shaft seal (1) for damage and/or contamination and replace if necessary.

* For the 4T45-E automatic transmission, refer to Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Right Side (Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Right Side) , or Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side (Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side)
* For the M86 manual transmission, refer to Front Wheel Drive Shaft Seal Replacement (Front Wheel Drive Shaft Seal Replacement).

Installation Procedure




1. Install the SA91112T into the transaxle output shaft seal (1).
2. Install the intermediate drive shaft into the transaxle until the drive shaft splines are past the seal (1), remove theSA91112T , then fully install the drive shaft.
3. Install, but DO NOT tighten the intermediate drive shaft bracket (2).




4. Position the vehicle speed sensor with the bracket to the intermediate drive shaft bracket, and install but DO NOT tighten the remaining intermediate drive shaft bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Tighten the upper bolt first.

5. Install the intermediate drive shaft bracket bolts and tighten to 50 Nm (37 lb ft).
6. Connect the electrical connector to the vehicle speed sensor.




7. Apply a very small amount of grease, GM P/N 1051344 (Canadian P/N 993037), or equivalent to the splines of the wheel drive shaft inner joint.
8. Install the wheel drive shaft into the intermediate drive shaft (1).
9. Verify that the wheel drive shaft is properly engaged:

* Grasp the inner tripod housing and pull the inner housing outward. Do NOT pull on the wheel drive axle shaft.
* The wheel drive shaft will remain firmly in place when properly engaged.

10. Connect the outer tie rod assembly to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Service and Repair).
11. Connect the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (Service and Repair).
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
13. Lower the vehicle.
14. Inspect the transaxle fluid level.