Output Shaft: Service and Repair

Output Shaft Replacement

Removal Procedure

1. Important: This procedure is for front-wheel-drive vehicles ONLY. The output shaft for all-wheel-drive vehicles is serviced with the transfer case which MUST be serviced with the transmission removed from the vehicle.

Disconnect the left and right drive axles from the transaxle.
2. Remove the case extension housing.
3. Remove the final drive differential.





4. Use the snap ring pliers in order to remove the compression ring (512) from the output shaft.

5. Important: Be careful not to damage the bearing on the output shaft.

Remove the output shaft through the left wheel opening.





6. Inspect the output shaft (510) and the bearing (511) for the following:
^ A cracked or deformed bearing cage
^ Damaged bushing journals
^ Stripped splines
^ A damaged retainer ring groove

Installation Procedure





1. Install the drive axle retaining ring (509) and the output shaft differential inboard snap ring (512) onto the output shaft (510).
2. Install the fourth clutch bearing (511) onto the output shaft (510).





3. Hold the final drive differential (700) in place and carefully install the output shaft (510) into the transmission through the left wheel opening and into the differential side gear.
4. Install the case extension housing.
5. Connect the left and right drive axles to the transaxle.