Drive Axles, Bearings and Joints: Service and Repair

Fig. 31 Intermediate shaft assembly. 1984---87 turbocharged models:

Fig. 32 Removing speedometer pinion from extension housing:

The intermediate shaft assembly, is used on all 1984---87 turbocharged models.

REMOVAL
1. Remove right driveshaft, refer to "Driveshaft, Replace" procedure.
2. Remove speedometer pinion from extension housing.
3. Remove two screws from bearing assembly bracket to engine block.
4. Remove intermediate shaft assembly from transaxle extension by pulling yoke outward.




SUBASSEMBLY SERVICE
UNIVERSAL JOINT & ROLLER
DISASSEMBLE
1. Mark relationship of shafts to insure proper alignment during assembly. Apply penetrating oil to bushing, then remove snap rings.
2. Support yoke in vise, then position 11-8 inch socket over bushing on top of yoke.
3. Strike socket with a suitable hammer until bushing moves up out of yoke into socket.
4. Turn assembly in vise and remove remaining bushings in same manner.

ASSEMBLE
1. Hold cross in position between yoke ears with one hand and start one bushing assembly into yoke with other hand.
2. Hammer bushing assembly into yoke, then install snap ring.
3. Install remaining bushing assemblies in same manner.

BRACKET, BEARING & SLINGER ASSEMBLY
DISASSEMBLE
1. Remove two bearing assembly to support bracket attaching screws, then separate bearing from bracket.
2. Press intermediate shaft out of bearing assembly and outer slinger. Do not dent or damage inner slinger or end of stub shaft.
3. If either slinger is damaged, it should be replaced by carefully pressing shaft through slinger. The bearing assembly is not serviceable and must be replaced as an assembly.

ASSEMBLE
1. Place new slinger on stub shaft, then using a suitable tool, drive slinger down until it bottoms out on shoulder of shaft. Ensure slinger is properly seated.
2. Press bearing assembly onto shaft, leaving a minimum of 1-32 inch (1 mm) clearance between slinger and bearing assembly. Apply pressure only to inner race of bearing assembly during installation.
3. Press outer slinger into position using a suitable tool. The slinger must bottom out on shoulder of shaft.

INSTALLATION
1. Attach bracket loosely to bearing assembly.
2. Hold stub yoke and install spline into transaxle.
3. Attach bracket to engine. Torque attaching screws to 40 ft-lbs. (54 Nm).
4. Push intermediate shaft assembly into transaxle as far as it can travel, then torque bracket to bearing attaching screws to 21 ft-lbs (28 Nm).
5. Apply suitable grease inside spline and pilot bore on bearing end of intermediate shaft.
6. Install speedometer pinion, then the right driveshaft, refer to "Driveshaft, Replace" procedure.