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Front Wheel Drive Shaft and Intermediate Shaft Assembly Replacement - Right Side (Diesel, FWD)

Front Wheel Drive Shaft and Intermediate Shaft Assembly Replacement - Right Side (Diesel, FWD)



Special Tools

CH-49376 Holding Wrench

CH-49400 Hub Spindle Remover

DT-6332 Seal Protector

EN-956-1 Extension


For equivalent regional tools, refer to Special Tools .

Removal Procedure


1.
Warning

To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control.


Warning

Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.


Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .

2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

3. Using the CH-49376 holding wrench (1) with EN-956-1 extension (2).


4.
Note

DO NOT re-use the wheel drive shaft nut. Discard the nut and replace with NEW.


Remove the wheel drive shaft nut (2) from the wheel drive shaft (1).


5.
Warning

Suspend the brake caliper with a strong steel wire or similar. This applies every time the caliper is removed from its mounting with the brake hose is still attached. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.


Using the CH-49400 remover (2), separate the brake rotor and wheel bearing/hub assembly (1).


6. Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

7. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement (GNA) Lower Control Arm Replacement (GNB) .

8. Drain the transmission fluid. Refer to Transmission Fluid Replacement .

9. Remove the fasteners (1) from the intermediate flange.


10.
Note

Discard the complete assembly.


Remove the wheel drive shaft and intermediate shaft assembly (2) through bracket.


Installation Procedure


1. Clean the mating faces of the intermediate shaft and the drive shaft.

Possible cleaner: brake cleaner (e.g. Loctite 7063)

2. Assemble rubber slinger (1).


3.
Note

It is not possible to install the bearing after the bonding is made.


Assemble bearing and flange onto intermediate shaft.

4. Apply Loctite 262 only to the drive shaft in the position shown (2). Container and brush have to be free from metal if used more than once.

5. Assemble drive shaft and intermediate shaft.

The bonding process takes 12 hours at room temperature. Let the bonding age either prior reinstallation into the car or after reinstallation. The vehicle must not be driven or moved when the adhesive dries. The vehicle can be pushed to a parking place while the adhesive dries.

6. Install the DT-6332 protector into the differential output shaft seal.


7. Reinstall the drive shaft and the intermediate shaft through the bracket onto the engine.

8.
Note

In order to prevent lubricant leaks, use care when installing the wheel drive shaft to the differential. Do not damage the oil seal. Replace the oil seal if it becomes nicked, distorted, or otherwise damaged.


Carefully install the intermediate shaft into the differential until the splines are past the DT-6332 protector.


9. Remove the DT-6332 protector from the differential output shaft seal.


10. Install the intermediate shaft into the differential until it is fully seated.

11. Refer to Fastener Caution .

Install the fasteners to the intermediate flange. Tighten fasteners to 22 Nm (16 lb ft) .

12. Install the front wheel drive shaft into the front wheel bearing/hub.

13. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement (GNA) Lower Control Arm Replacement (GNB) .

14. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

15. Install the NEW wheel drive shaft nut (2) to the wheel drive shaft (1) tighten in 3 passes.


16. Using the CH-49376 holding wrench (1) with EN-956-1 extension (2).


17. Using a torque wrench and the appropriate size socket, tighten the wheel drive shaft nut to 150 Nm (111 lb ft) .

Release the wheel drive shaft nut through 45° .

Tighten the drive shaft nut to 250 Nm (185 lb ft) .

18. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

19.
Note

The bonding process takes 12 hours at room temperature. Let the bonding age either prior reinstallation into the car or after reinstallation.

The vehicle must not be driven or moved when the adhesive dries. The vehicle can however be pushed to a parking place while the adhesive dries.


Fill up the transmission fluid. Refer to Transmission Fluid Replacement .