Diesel And Turbo Models

Fig 1: Wheel and Tire Removal

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1 - WHEEL/TIRE ASSY.

2 - LUG NUT (5)

3 - HUB

CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.

CAUTION: The halfshaft, 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 halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N.m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.

Disconnect battery negative cable.
Place transaxle in gated park.
Raise vehicle on hoist.

Remove wheel and tire (1) assembly. See Fig 1.

Fig 2: Halfshaft Retaining Hardware

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1 - COTTER PIN

2 - WASHER

3 - HUB NUT

4 - SPRING WASHER

5 - NUT LOCK

Remove the cotter pin (1) , nut lock (5), and spring washer (4), and hub nut (3) from the end of the outer CV joint stub axle. See Fig 2.

Fig 3: Steering Knuckle at Lower Control Arm Ball Joint
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1 - NUT

2 - BOLT

3 - BALL JOINT
If equipped with ABS, disconnect the front wheel speed sensor and secure harness out of the way.

Remove nut and bolt (1,2) retaining ball joint stud (3) into steering knuckle. See Fig 3.

Fig 4: Separating Lower Control Arm from Steering Knuckle

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1 - STEERING KNUCKLE

2 - PRY BAR

3 - LOWER CONTROL ARM

4 - BALL JOINT STUD

NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.

Separate ball joint stud (4) from steering knuckle by prying down on lower control arm (3). See Fig 4.

Fig 5: Separating Halfshaft from Hub/Bearing
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1 - PULLER 1026

2 - HALFSHAFT

NOTE: Care must be taken not to separate the inner CV joint during this operation. Do not allow halfshaft to hang by inner CV joint, halfshaft must be supported.
Remove halfshaft (2) from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. See Fig 5. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from hub is encountered, do not strike shaft with hammer, instead use Puller 1026 (1) to separate.

Fig 6: Applying Grease To Face Of Outer CV
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Support outer end of the halfshaft assembly (1) . See Fig 6.

Fig 7: Halfshaft and Intermediate Shaft - 2.2L Turbo Diesel

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1 - HALFSHAFT (LH)

2 - TRANSAXLE

3 - INTERMEDIATE SHAFT

4 - BOLT (3)

5 - HALFSHAFT (RH)

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. DO NOT PULL ON INTERCONNECTING SHAFT TO REMOVE, AS THE INNER JOINT WILL BECOME SEPARATED.

NOTE: When left halfshaft is removed from transaxle, some fluid may leak out.

Remove halfshaft(s) (1,5) . See Fig 7. Left halfshaft: While applying outward pressure on joint by hand, dislodge inner tripod joint from differential side gear by striking outward with a punch at extraction groove. When removing tripod joint and halfshaft, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Right halfshaft: Slide inner tripod joint off of intermediate shaft. If difficulty is encountered, dislodge joint from intermediate shaft using punch.

Fig 8: Halfshaft and Intermediate Shaft - 2.4L Turbo Models

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1 - HALFSHAFT (LH)

2 - TRANSAXLE

3 - BOLT

4 - INTERMEDIATE SHAFT

5 - HALFSHAFT (RH)

6 - BOLT (2)

NOTE: When left halfshaft is removed from transaxle, some fluid may leak out.

Remove halfshaft(s) (1,5) . See Fig 8. Left halfshaft: While applying outward pressure on joint by hand, dislodge inner tripod joint from differential side gear by striking outward with a punch at extraction groove. When removing tripod joint and halfshaft, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Right halfshaft: Slide inner tripod joint off of intermediate shaft. If difficulty is encountered, dislodge joint from intermediate shaft using punch.
If intermediate shaft is to be removed, remove three intermediate shaft bearing-to-bracket bolts. 2.4L turbo models utilize two (2) intermediate shaft bearing-to-bracket bolts. Remove intermediate shaft bearing/shaft assembly from transaxle.
CAUTION: The halfshaft, 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 halfshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N.m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.