Removal Procedure
Tools Required
• | J 42066 Wheel
Hub Flange Holding Adapter |
- Place the gear selector in the NEUTRAL position.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the tire and wheel assembly. Refer to
Wheel Removal
.
- Install the J 42066
to the wheel hub flange with the wheel bolts.
- Remove the bolts (1) from the drive axle flange
(2) while holding the J 42066
with a ratchet.
- Separate the outer end of the drive axle from
the wheel bearing hub inner flange.
Important: Ensure that the beveled side of the J 42071
, labeled Differential Side, is against the differential and
not against the drive axle or damage to the ABS sensor reluctor ring may occur.
- Use the J 42071
and
a deadblow hammer to separate the drive axle from the rear axle differential.
- Remove the drive axle from the vehicle.
- Clean the drive axle spline.
- Clean the seal surfaces.
GKN Drive Axle Disassembly
Important: The following overhaul procedures apply to the outer constant velocity
joint only. The inner joint cannot be serviced. If the inner joint requires
service, the entire drive axle assembly must be replaced.
The GKN drive axle is identified by its shaft diameter and by the axle
manufacturer's markings on the outer surface of the inner joint. This marking
contains the Made in Germany phrase along with some other manufacturing data.
The diameter of the GKN axle shaft should measure about 32.1 mm (1.26 in).
The Delphi/Saginaw axle will most likely be found on mid year and on later
Cateras. The Delphi/Saginaw axle contains slightly smaller drive axle shafts
measuring 27.7 mm (1.09 in) in diameter.
- Clean the outside of the drive axle using a suitable solvent before
disassembling.
- Clamp the drive axle at the shaft surface in a soft metal-jawed
vice.
- Using tin snips or another suitable cutting tool,
cut both the inner (3) and outer (1) boot retaining clamps in the raised crimp
area.
- Perform the step that applies below:
• | If replacing the boot, remove the clamps. |
• | If not replacing the boot, slide the cap and the boot slightly
down the axle shaft in order to expose the outer constant velocity joint without
destroying the clamps. |
- Using a suitable drift and a hammer, tap the
inner/outer dust shield caps away from both sides of the outer constant velocity
joint.
- Clean away any grease from the following components:
• | The outer constant velocity joint |
- Remove the retaining ring (1) from the drive
axle shaft (2).
- Discard the retaining ring.
- Remove the drive axle shaft from the vice.
- Slide the inner dust shield boot and cap toward the center of
the shaft in order to expose the bottom of the outer constant velocity joint.
Important: Inspect that the inner race is fully supported in the press during the
next step.
- Install the drive axle onto a press, ensuring that the inner race is
fully supported.
Important: Do not attempt to disassemble the outer constant velocity joint until
the joint is removed from the drive axle shaft.
- Press the drive axle shaft from the outer constant velocity joint.
- If replacing or removing the boot for cleaning, perform the following
steps:
13.1. | Loosen the inner boot clamp. |
13.2. | Carefully slide the boot and the dust shield off of the drive
axle shaft in order to prevent damage to the boot from the shaft spline edges. |
- Clean the following components using a suitable solvent:
14.1. | The drive axle shaft |
- Inspect the drive axle shaft for twisting, cracking, or excessive
spline wear. Replace as needed.
- Inspect the boots for splits, fatigue, cracks, or wear. Replace
as needed.
- If replacing the drive axle, remove the ABS sensor reluctor ring
from the inner constant velocity joint.
GKN Outer Constant Velocity Joint Disassembly
Important:
• | Complete disassembly of the outer constant velocity joint is not
recommended. The internal components are a precision fit and develop their
own characteristic wear patterns. |
• | Do not intermix components from another joint. This may result
in looseness, binding, or premature failure of the joint. |
• | Should the joint become inadvertently disassembled, follow the
assembly procedure EXACTLY. |
Inspection
- Inspect the grease in the joint:
• | If contaminated, replace the joint. |
• | If not contaminated, clean the joint using a suitable solvent. |
- Tilt the inner race to one side in order to expose each ball bearing
for inspection.
- Replace the joint if any of the following conditions exist:
• | Any severe pits, galls, or play between the balls and the cage
windows |
• | Any cracks or other damage to the cage |
• | Any pits, galls, or chips in the raceway |
- If the joint becomes disassembled during the
inspection, perform the following steps:
4.1. | Note the identification groove (1) on the outer race and identification
step (2) of the inner race for proper orientation upon reassembly. |
4.2. | Refer to the Important notice above before reassembling. |
GKN Outer Constant Velocity Joint Assembly
- Lightly grease the inner/outer race ball bearing contact surfaces.
- Position the inner race in the center of the
cage.
- Place the inner race/cage assembly (2) into the
outer race (1), using the markings as noted during disassembly.
- Inspect that the identification markings on both
the inner (2) and outer (1) races are on opposite sides.
- Align the thick sections on the outer race (2)
with the narrow sections on the inner race (1).
- Tilt the cage and inner race, fitting each ball
one at a time.
- Inspect the plunge movement:
Specification
Plunge movement (approx.): 8.5 mm (0.33 in)
- If no plunge movement can be achieved, perform the following steps:
• | Repeat the assembly procedure until plunge movement can be achieved. |
GKN Drive Axle Assembly
Tools Required
J 35566 Service
Boot Clamp Pliers
- Remove the old silicone sealing bead from the dust shield caps
and the outer constant velocity joint surfaces.
- Clean the dust shield cap and outer constant velocity joint surfaces.
- Install the drive axle boot onto the drive axle shaft.
- Install the dust shield cap onto the drive axle shaft.
Important: The joint inner race should take the pressing load during the next step.
- Press the outer constant velocity joint onto the drive axle shaft:
5.1. | Point the inner race identifying step toward the shaft shoulders. |
5.2. | Point the outer race identifying channel away from the shaft. |
- Install a new drive axle retaining ring (1).
- Apply a 2 mm bead of RTV to both cap surfaces.
- Allow the RTV to cure for about one hour.
- Pack the inside section of the joint and boot with 40 g
of grease.
- Pack the outside section of the joint with 20 g of grease.
- Position the inner/outer dust shield caps (1) onto the outer constant
velocity joint, aligning all bolt holes.
- Using a soft-faced mallet, tap the dust shields into place on
the joint.
- Locate the ends of the boot into the boot groove
on the dust shield cap and shaft, if removed.
- Move the small end of the boot up the shaft to the joint in order
to purge any air pressure in the boots and work out any dimples before applying
new clamps.
- Position a small clamp over the small end of
the boot at the drive axle shaft.
- Using the J 35566
, crimps the clamp end.
- Position the large clamp over the large end of the boot at the
drive axle shaft.
- Using the J 35566
, crimps the clamp end.
Installation Procedure
- Lubricate the drive axle spline with differential lubricant.
- Lubricate the seal surfaces with differential lubricant.
Important: Use only enough force necessary to seat the drive axle into the rear
axle differential.
- Use a rubber faced mallet to drive the outer end of the drive axle to
install the drive axle into the differential bore.
- Position the other end of the drive axle into the wheel bearing
hub inner flange.
- Use a ratchet to hold the J 42066
while installing the bolts to the drive
axle flange.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the bolts to 50 N·m (37 lb ft) +
67 degrees.
- Remove the J 42066
from the wheel hub flange.
- Install the tire and wheel assembly. Refer to
Wheel Installation
.
- Lower the vehicle.