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Fig. 13 G.K.N. Tripod Thick Ring Side

Fig. 14 G.K.N. Tripod Circlip Side

(4) Install the snap ring into the groove on the interconnecting shaft to lock the tripod in position (Fig. 16)

Should the wire ring tripod retainer not be suitable for reuse or a new one is not available,the following procedure should be used:

(1)Install tripod on the shaft.

(2)Install spring and cup assembly into inner joint housing.

(3)Position small end of boot in locating grooves on the interconnecting shaft.

Fig. 15 Tripod Snap Ring Installation

Fig. 16 Tripod Installation

(4)Clamp the small end boot clamp onto boot, retaining boot to the interconnecting shaft.

(5)Distribute 1/2 packet of grease into boot and 1/2 into housing.

(6)Install tripod into housing.

(7)Place large clamp over shaft.

(8)Install driveshaft into vehicle, see Driveshaft Install.

(9)Position large end of boot into locating groove.

(10)Slide large clamp into position.

(11)See Boot Install for clamping instructions.

TRIPOD ASSEMBLY INSTALLATION S.S.G. & G.K.N. WITH SINGLE RING RETENTION

(1)Fasten the (new) boot to the interconnecting shaft. See Boots Install.

(2)Install the tripod assembly onto the interconnecting shaft until it is past the snap ring groove on the shaft (Fig. 17). If required the tripod assembly can be tapped onto the interconnecting shaft using a brass drift, on the body of the tripod assembly (Fig. 4). Do not hit the outer tripod assembly bearings in an attempt to install tripod on interconnecting shaft.

2 - 36 SUSPENSION/DRIVESHAFTS

Fig. 17 Interconnecting Shaft Snap Ring Groove

(3) Install a NEW outer tripod assembly to interconnecting shaft retaining snap ring, into the interconnecting shaft snap ring groove (Fig. 18). Be sure that the snap ring is fully seated into the snap ring groove around the entire interconnecting shaft.

Fig. 18 Outer Tripod Retaining Snap Ring Installa-

tion

TRIPOD ASSEMBLY INSTALLATION G.K.N. WITH DOUBLE RING RETENTION

(1)Fasten the (new) boot to the interconnecting shaft. See Boots Install.

(2)Install the inner tripod assembly retaining snap ring into the retaining groove on the interconnecting shaft (Fig. 19).

(3)Install the tripod assembly onto the interconnecting shaft until it is past the outer snap ring groove on the shaft (Fig. 17). If required the tripod assembly can be tapped onto the interconnecting shaft using a brass drift, on the body of the tripod assembly (Fig. 4). Do not hit the outer tripod assembly bearings in an attempt to install tripod on interconnecting shaft.

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Fig. 19 Inner Snap Ring Installation

(4) Install the outer tripod assembly to intermediate shaft retaining snap ring into the snap ring groove on the intermediate shaft (Fig. 20).

Fig. 20 Outer Snap Ring Installation

INNER C/V JOINT HOUSING INSTALLATION

G.K.N.

(1)Distribute 1/2 the amount of the grease provided into the housing and the remaining amount into the boot.

(2)Position the spring in the housing spring pocket with the spring cup attached to the exposed end of the spring (Fig. 21). Place a small amount of grease on the concave surface of the spring cup.

CAUTION: Care must be taken to ensure proper spring positioning. The spring must remain centered in the housing spring pocket when the tripod is installed and seated in the spring cup (Fig. 13).

(3) Clamp the stub shaft of the housing in a vise.

Use protective caps on jaws of vise so stub shaft does not get damaged by the vise. Position the interconnecting shaft and the tripod assembly on top of

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Fig. 21 Spring and Cup Installation

the plastic retaining collar. Carefully insert each of the tripod rollers into the retaining collar, one at a time while holding the interconnecting shaft on an angle. Carefully push down on the shaft until the rollers are locked into retaining collar in the housing.

(4) Position the boot over the boot retaining groove in the housing and clamp in place. See Boots Install.

S.S.G.

(1)Distribute 1/2 the amount of the grease provided into the housing and the remaining amount into the boot.

(2)Position the spring in the housing spring pocket with the spring cup attached to the exposed end of the spring (Fig. 21). Place a small amount of grease on the concave surface of the spring cup.

CAUTION: Care must be taken to ensure proper spring positioning. The spring must remain centered in the housing spring pocket when the tripod is installed and seated in the spring cup (Fig. 21).

(3)Slip tripod into housing and install the tripod wire retaining ring into position. Check for the ability of the retaining ring to hold the tripod in the housing.

(4)Position the boot over the boot retaining groove in the housing and clamp in place. See Boots Install.

OUTER C/V JOINT

DISASSEMBLE

(1)Remove boot clamps on boot and discard (Fig.

1).

(2)Wipe away grease to expose joint.

(3)G.K.N. Remove outer C/V Joint from shaft by supporting the interconnecting shaft in a vise. Use protective caps on the jaws of the vise to prevent damage to the interconnecting shaft. Give a sharp tap to the top of housing to dislodge joint from internal circlip installed in a groove at the outer end of the shaft (Fig. 2).

SUSPENSION/DRIVESHAFTS 2 - 37

Fig. 1 Outer C/V Joint Components

Fig. 2 Remove Joint from Shaft .

S.S.G. A single circlip located in a groove on the cross, is used to retain the cross to the shaft (Fig. 3). Loosen the damper weight bolts and slide it and the boot towards the inner joint. Expand the circlip with snap ring pliers and slide joint from shaft. Install damper weight, see Damper Weights.

WEAR SLEEVE

A wear sleeve installed on the outer C/V joint housing (Fig. 1) provides a wipe surface for the hub bearing seal (installed in the steering knuckle).

(4)If bent or damaged, carefully pry wear sleeve from C/V joint machined ledge.

(5)Remove circlip from shaft groove and discard (Fig. 4). A replacement boot package will include this circlip.

(6)Unless the shaft is damaged and needs replacing, do not remove the heavy spacer ring from the shaft, G.K.N. only (Fig. 4).

(7)With joint separated from the interconnecting shaft proceed as follows:

Fig. 3 Circlip Retainer in Cross S.S.G.

Fig. 4 Remove Circlip

Fig. 5 Rotate Cage & Cross to Remove Balls

²If outer C/V joint was operating satisfactorily and grease does not appear to be contaminated, just replace boot. Bypass the following disassembly procedure for the C/V joint assembly, See Boots Install.

²If outer joint is noisy or badly worn. Bypass the following disassembly and replace entire unit. It is

Fig. 6 Ball Released

also recommended that the boot be replaced. The Boot Package includes the boot, clamps, retaining ring (circlip), and lubricant. See boots install.

(8)Hold joint vertically in vise by clamping on splined shaft, using soft jaws to prevent damage.

(9)Wipe off surplus grease and mark relative position of inner cross, cage and housing with a dab of paint (Fig. 5).

(10)Press down on one side of inner race to tilt cage and remove ball from opposite side (Figs.5 and 6). If joint is tight, use a hammer and brass drift to tap inner race. Do not hit the cage. Repeat this step until all 6 balls are removed. A screwdriver may be used to pry balls loose.

(11)Tilt the cage and inner race assembly vertically and position two opposing cage windows in area between the ball grooves. Remove the cage and inner race assembly by pulling upward away from the housing (Fig. 7).

(12)Turn inner cross (driver) 90° to cage and align one of the race spherical lands with cage window. Raise land into cage window and remove inner race by swinging out (Fig. 8).

INSPECT

Check grease for contamination and all parts for defects as follows:

(1)Wash all parts in suitable solvent and dry, preferably with compressed air.

(2)Inspect housing ball races for excessive wear and scouring.

(3)Check splined shaft and nut threads for dam-

age.

(4)Inspect all 6 balls for pitting, cracks, scouring and wear. Dulling of surface is normal.

(5)Inspect cage for excessive wear on inside and outside spherical surfaces, surface ripples on cage window, cracks, and chipping.

Fig. 7 Removing Cage & Cross Assembly from Housing

Fig. 8 Removing Cross from Cage

(6) Inspect inner race (cross) for excessive wear or scouring of ball races.

Any of the above defects will warrant replacing the C/V assembly as a unit.

Polished areas in races (cross and housing) and on cage spheres are normal and do not indicate need for joint replacement. Unless they are suspected of causing noise and vibration.

ASSEMBLE

If outer joint was not disassembled nor the wear sleeve damaged go to step 11.

(1) Position new wear sleeve on joint housing machined ledge (Fig. 1). Assemble Installer, Special Tool C-4698 (Tool is provided with handle and dual purpose drive head for installing wear sleeve onto C/V

Fig. 1 Tool Set-Up for Wear Sleeve Installation

Fig. 2 Installing Cross into Cage

Fig. 4 Installing Cage & Cross into Housing

Fig. 5 Cage & Cross Assembled S.S.G.

(6) Align opposing cage windows with housing land and feed cage assembly into housing (Fig. 4).

Fig. 7 Inserting Balls into Raceway

(9) Fasten boot to shaft. See Boots Install.

Fig. 8 Installing New Circlip

(10)On G.K.N. units insert the new circlip, provided with kit in shaft groove. Do not over expand or twist circlip during assembly (Fig. 8). The S.S.G. unit has a reusable circlip retainer that is an integral part of driver assembly.

(11)Position outer joint on splined end with hub nut on stub shaft. Engage splines, and tap sharply with mallet (Fig. 9).

(12)Check that circlip is properly seated by attempting to pull joint from the shaft.

(13)Locate large end of boot over joint housing checking that boot is not twisted.

(14)Fasten boot to housing. See Boots Install.

Fig. 9 Position Joint onto Shaft Splines

INTERMEDIATE SHAFT ASSEMBLY RECONDITION

Reconditioning of the Intermediate Shaft Assembly (Fig. 1) for the Equal Length Drive Shaft System vehicles is the same for the manual and automatic transaxles.

INTERMEDIATE SHAFT ASSEMBLY

Remove

(1)Remove right driveshaft. See Driveshaft Assemblies Remove.

(2)Remove speedometer pinion from the extension housing (Fig. 2).

(3)Remove the two bolts which mount the bearing assembly bracket to the engine block (Fig. 1).

Fig. 2 Remove Speedometer Pinion

(4) Remove assembly from transaxle extension by pulling outward on the yoke (Fig. 3).

Fig. 3 Removing Intermediate Shaft Assembly

UNIVERSAL JOINT AND ROLLER

Disassemble

(1)Mark relationship of shaft to shaft to ensure proper alignment at assembly. Apply penetrating oil to bushings and remove snap rings.

(2)Support yoke in vise and place a socket large enough to receive bushing on top of yoke. A 1-1/8 inch socket is suitable (Fig. 4).

(3)Striking socket with hammer will cause yoke to move down and bushing to move up out of yoke into socket.

(4)After removing one bushing, turn parts in a vise and remove other bushing in same manner.

Fig. 4 Disassemble Universal Joint

Fig. 5 Assemble Universal Joint

Assemble

(1)Hold cross in position between yoke ears with one hand and start one bushing assembly into yoke with other hand (Fig. 5).

(2)Continue to hold cross in position, then hammer bushing assembly into yoke and install snap ring.

(3)Install opposite bushing and snap ring in the same manner.

(4)Repeat process for stub shaft yoke after aligning marks on yoke and shaft.