Output Shaft Replacement M15

Tool Required

J 42562 Axle Removal Wedge

1. Remove the case extension housing. Refer to Case Extension Replacement .
2. Disconnect the left drive axle from the transaxle. Refer to Front Wheel Drive Shaft Replacement .



3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position.
4. Place the J 42562 between the end of the output shaft and the differential pinion shaft.
5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear.



6. Remove the differential carrier (700).
7. Using snap ring pliers remove the compression ring from the output shaft.

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

8. Remove the output shaft through the left wheel opening.



9. 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

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 front differential carrier in place and carefully install the output shaft (510) into the transmission through the left wheel opening. Extend the output shaft through the differential side gear.
4. Install the case extension housing. Refer to Case Extension Replacement .
5. Connect the left drive axle to the transaxle. Refer to Front Wheel Drive Shaft Replacement .

Output Shaft Replacement M76

Tool Required

J 42562 Axle Removal Wedge

Important: The transmission-to-transfer case end play check procedure must be performed each time the transmission, transfer case, or the internal components (excluding gaskets and seals) are replaced.

1. Remove the Engine /Transaxle assembly . Refer to Engine Replacement in Engine Mechanical-3.4L.
2. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement .



3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position.
4. Place the between J 42562 the end of the output shaft and the differential pinion shaft.
5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear.



6. Remove the differential carrier (700).
7. Using snap ring pliers remove the compression ring (512) from the output shaft.

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

8. Remove the output shaft through the left wheel opening.



9. 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

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 front differential carrier (700) in place and carefully install the output shaft (510) into the transmission through the left wheel opening. Extend the output shaft through the differential side gear.
4. Install the transfer case assembly. Refer to Transfer Case Assembly Replacement .
5. Install the Engine /Transaxle assembly . Refer to Engine Replacement in Engine Mechanical-3.4L.