2005 axle shafts

2005 Driveline/Axle

Wheel Drive Shafts - L300

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Fastener Tightening Specifications

COMPONENT LOCATOR

WHEEL DRIVE SHAFTS DISASSEMBLED VIEWS

ApplicationSpecification

Metric EnglishAxle Shaft-to-Hub

� Initial Torque 100-160 N.m 74-118 lb ft

� Final Torque 20 N.m + 90 degrees 15 lb ft + 90 degrees

Lower Control Arm-to-Steering Knuckle 100 N.m 75 lb ftTie Rod End Linkage Installer 45 N.m 33 lb ftTie Rod End-to-Steering Knuckle Nut 60 N.m 44 lb ft

2005 Saturn L300

2005 Driveline/Axle Wheel Drive Shafts - L300

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Monday, May 09, 2011 11:29:46 AM © 2006 Mitchell Repair Information Company, LLC.

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Monday, May 09, 2011 11:29:49 AM Page 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 1: Exploded View Of Wheel Drive Shafts Courtesy of GENERAL MOTORS CORP.

Callouts For Fig. 1 Callout Component Name

1 Retaining Ring2 Retainer and Housing Assembly3 Housing Assembly4 Tripot Joint Spider Assembly5 Boot Retaining Clamp6 Tripot Joint Boot7 Swage Ring8 Halfshaft Bar

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DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - WHEEL DRIVE SHAFTS

Begin the wheel drive shaft system diagnosis with the Diagnostic Starting Point - Vibration Diagnosis and Correction in Vibration Diagnosis and Correction. The use of the Diagnostic Starting Point will help determine if the concern is wheel drive shaft related. When instructed to exit the Vibration Diagnosis and Correction diagnostic procedures, return to the Diagnostic Starting Point - Wheel Drive Shafts and proceed to Wheel Drive Shafts Description and Operation in order to become familiar with the design and function of the wheel drive shaft system. Reviewing the Description and Operation information will also help determine if the condition is a potential operating characteristic or not.

SYMPTOMS - WHEEL DRIVE SHAFTS

1. Review the Diagnostic Starting Point - Vibration Diagnosis and Correction in Vibration Diagnosis and Correction.

2. Perform the Vibration Analysis - Road Testing in Vibration Diagnosis and Correction in order to effectively diagnose the concern.

3. Review the system operation in order to become familiar with the system function. Refer to Wheel Drive Shafts Description and Operation.

Visual/Physical Inspection

� Inspect for aftermarket equipment and modifications which could affect the operation of the wheel drive shafts or other rotating components.

� Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

� Thoroughly inspect the entire wheel drive shaft for visible damage, leaking joint seals, and missing seal clamps.

9 Retaining Ring10 Swage Ring11 CV Joint Boot12 Boot Retaining Clamp13 Chrome Alloy Ball14 CV Joint Inner Race15 CV Joint Cage16 CV Joint Outer Race (ABS)17 CV Joint Outer Race (NON ABS)18 Washer19 Nut

IMPORTANT: Complete the following steps prior to beginning the wheel drive shaft diagnosis.

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� Inspect the wheel drive shaft seals for cuts, tears, or other damage which may allow the loss of lubricant and the entry of contaminates.

Symptom List

After performing the Visual/Physical Inspection and no visual signs of damage or other interference impairing the wheel drive shaft function is apparent, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the joints manually. Any binding or otherwise impeded movement of the joints may indicate damage which could contribute to the concern. Refer to the following:

� Click Noise In Turns

� Clunk When Accelerating from Coast � Clunk Noise When Accelerating During Turns

� Shudder or Vibration During Acceleration

CLICK NOISE IN TURNS

A click noise occurring during turns may be caused by a worn or damaged wheel drive shaft outer joint. This may be more apparent while simultaneously turning and accelerating. This click is caused by wear and/or damage to the constant velocity joint bearings and/or races. Commonly, this damage or wear is caused by the loss of lubricating grease from the constant velocity joint and the entry of foreign material or contaminates.

Carefully inspect the wheel drive shaft seals for cuts, tears or other damage which may allow the lubricating grease to escape. The loss of this grease will cause damage to the wheel drive shaft constant velocity joint in a very short period of time.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the outer joint manually. Any binding or impeded movement of the joint may indicate damage which could contribute to the concern.

CLUNK WHEN ACCELERATING FROM COAST

A clunk noise occurring when accelerating from coast or a standing start may be caused by a worn or damaged wheel drive shaft inner joint. The common cause of wheel drive shaft inner joint damage is the loss of lubricating grease and/or the presence of foreign material and contaminates in the joint. This usually occurs as a result of a torn or damaged inner joint seal.

Carefully inspect the wheel drive shaft seal for cuts, tears or other damage that may allow the loss of the lubricating grease and/or the entry of contaminates.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the inner joint manually. Do not allow the joint to separate from the wheel drive shaft bar. Any binding or impeded movement of the joint may indicate damage which could contribute to the concern.

CLUNK NOISE WHEN ACCELERATING DURING TURNS

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A clunk noise that occurs while accelerating during turns may be caused by wear and/or damage to the inboard and the outboard joints in combination. The loss of lubricant and/or the presence of contaminates can cause damage to the internal components of the joints.

Carefully inspect the joint seals for cuts, tears or other damage. Joint seals that are damaged may allow lubricant leakage and the entry of contaminates.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the joints manually. Do not allow the joints to separate from the wheel drive shaft bar. Any binding or impeded movement of the joints may indicate damage which could contribute to the concern.

SHUDDER OR VIBRATION DURING ACCELERATION

In order to diagnose a shudder or vibration during acceleration, refer to Diagnostic Starting Point - Vibration Diagnosis and Correction in Vibration Diagnosis and Correction.

REPAIR INSTRUCTIONS

WHEEL DRIVE SHAFT REPLACEMENT

Tools Required

� J 44015 Steering Linkage Installer. See Special Tools.

� SA91100C Tie Rod Separator. See Special Tools.

Removal Procedure

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Fig. 2: Removing & Installing Drive Axle Nut & Cotter Pin Courtesy of GENERAL MOTORS CORP.

1. With the vehicle on the ground, depress the brake pedal and remove the cotter and drive axle nut. Discard the nut and cotter.

2. Raise the vehicle on a hoist.

3. Remove the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

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Fig. 3: View Of Tie Rod End To Steering Knuckle Courtesy of GENERAL MOTORS CORP.

4. Remove the tie rod end torque prevailing nut and discard the nut.

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Fig. 4: Separating Outer Tie Rod End From Steering Knuckle Courtesy of GENERAL MOTORS CORP.

5. Using the SA91100C , separate the tie rod end from the steering knuckle. See Special Tools.

NOTE: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

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Fig. 5: Disconnecting Lower Control Arms Courtesy of GENERAL MOTORS CORP.

6. Remove the lower control arm to steering knuckle nut and bolt.

7. Separate the lower control arm from the steering knuckle.

IMPORTANT: If difficulty is encountered in separating the axle from the hub, tap on the end of the drive axle, using a block of wood and a hammer. Do not hammer directly on the end of the axle.

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Fig. 6: Separating Drive Axle From Wheel Hub Courtesy of GENERAL MOTORS CORP.

8. While pulling the knuckle/strut assembly away from the vehicle, pull the outer end of the drive axle out of the wheel hub.

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Fig. 7: Supporting Drive Axle Assembly Courtesy of GENERAL MOTORS CORP.

9. Support or suspend the drive axle assembly.

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Fig. 8: Removing Drive Axle From Transaxle Courtesy of GENERAL MOTORS CORP.

10. Remove the drive axle from the transaxle.

IMPORTANT: Before removing the drive axle, place an approved container under the transaxle to catch any fluid spillage.

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Fig. 9: Removing Stub Shaft Retaining Ring Courtesy of GENERAL MOTORS CORP.

11. Remove the shaft retaining the ring from the end of the drive axle or stub shaft and discard. The stub shaft is shown.

Installation Procedure

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Fig. 10: Removing Stub Shaft Retaining Ring Courtesy of GENERAL MOTORS CORP.

1. Install a new axle or stub shaft retaining ring.

2. Insert the drive axle into the transaxle.

IMPORTANT: Apply output shaft lubricant Saturn P/N 7847638 to the splines of the output shaft before installation.

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Fig. 11: Inserting Drive Axle Into Wheel Hub Courtesy of GENERAL MOTORS CORP.

3. After the drive axle splines have safely passed the transaxle oil seal, remove the seal protector and fully seat the drive axle into the transaxle.

4. Insert the outer end of the drive axle into the wheel hub. Install the drive axle to hub washer and the new nut.

IMPORTANT:� Use a new nut. The torque retention of the old nut may not be

sufficient. � Do not tighten the fastener at this time.

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Fig. 12: Disconnecting Lower Control Arms Courtesy of GENERAL MOTORS CORP.

5. Install the lower control arm ball stud into the steering knuckle. Hold the bolt stationary and tighten the nut.

Tighten: Tighten the lower control arm-to-steering knuckle to 100 N.m (75 lb ft).

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: Use a new nut and bolt. The torque retention of old fasteners may not be sufficient.

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Fig. 13: View Of Tie Rod, Knuckle & Tapered Ball Stud Courtesy of GENERAL MOTORS CORP.

6. Install the tie rod end into the steering knuckle.

7. Using the J 44015 , or equivalent, seat the tie rod end into knuckle. See Special Tools.

Tighten: Tighten the tie rod end linkage installer to 45 N.m (33 lb ft).

IMPORTANT: The tie rod ends must be thoroughly cleaned before installing and tightening.

IMPORTANT: Use a new nut. The torque retention of the old nut may not be sufficient.

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8. Inspect the boot for damage and replace any part if damaged.

Fig. 14: View Of Tie Rod End To Steering Knuckle Courtesy of GENERAL MOTORS CORP.

9. Remove the linkage installer and install the NEW tie rod end nut.

Tighten: Tighten the tie rod end-to-steering knuckle nut to 60 N.m (44 lb ft).

10. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

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Fig. 15: Removing & Installing Drive Axle Nut & Cotter Pin Courtesy of GENERAL MOTORS CORP.

11. Lower the vehicle from the hoist.

12. Tighten the axle shaft to hub nut in the following sequence.

Tighten: � Tighten the axle shaft-to-hub - initial torque to 100-160 N.m (74-118 lb ft) then release nut until it

is free to turn by hand.

� Tighten the axle shaft-to-hub - final torque to 20 N.m (15 lb ft) + 90 degrees. If required, continue turning nut until a hole for the cotter pin is aligned properly.

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13. Install the cotter pin.

WHEEL DRIVE SHAFT INNER JOINT AND SEAL REPLACEMENT

Tools Required

� SA9203C Axle Clamp Installer. See Special Tools.

� SA9198C C/V Joint Snap Ring Pliers. See Special Tools.

� SA9161C Axle Boot Clamp Installer. See Special Tools.

Disassembly Procedure

1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement. 2. Disconnect the swage ring from the half shaft bar using a hand grinder to cut through the ring, taking care

not to damage the half shaft bar.

NOTE: Use soft metal or wood in between vice jaws to protect the shaft.

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Fig. 16: Removing Large Seal Retaining Clamp Courtesy of GENERAL MOTORS CORP.

3. Remove large seal retaining clamp. Using a small blade screwdriver release the clamp and discard.

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Fig. 17: Separating Boot From Tripot Housing At Large Diameter End Courtesy of GENERAL MOTORS CORP.

4. Separate the boot from the tripot housing at the large diameter and slide the boot away from the joint along the axle shaft.

5. Wipe the excess grease from the face of the tripot spider and the inside of the tripot housing.

6. Remove the tripot housing from the spider and shaft.

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Fig. 18: Removing & Installing Spider Assembly Courtesy of GENERAL MOTORS CORP.

7. Remove the spider retaining ring from the groove on the axle shaft and slide the spider assembly off of the shaft.

8. Remove the boot from the axle shaft.

9. Clean the tripot joint spider assembly and the housing thoroughly with cleaning solvent.

10. Remove all traces of old grease and any contaminants. Dry all the parts.

11. Inspect the tripot joint components for unusual wear, cracks, and other damage. Replace any needed components.

Assembly Procedure

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Fig. 19: Installing Small Swage Ring Clamp Courtesy of GENERAL MOTORS CORP.

1. Install the small swage ring clamp onto the neck of the inner boot. Do not crimp.

2. Slide the inner boot onto the shaft and locate the neck of the boot in the proper position in the boot groove on the axle shaft.

3. Swage the boot retaining clamp withSA9203C Axle Boot Clamp Installer, (or equivalent) as shown. See Special Tools.

IMPORTANT: Check clamp location during swage operation to make sure it is positioned correctly around the entire circumference.

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4. Measure the clamp end gap, and repeat step 3 if necessary. The dimension should not exceed 2.15 mm (0.85 in).

Fig. 20: Removing & Installing Spider Assembly Courtesy of GENERAL MOTORS CORP.

5. Slide the tripot spider assembly past the spider retaining ring groove, until seated against shoulder.

6. Install the spider retaining ring in the groove of the axle shaft withSA9198C CV Joint Snap Ring Pliers, (or equivalent). See Special Tools.

7. Place approximately half of the grease (provided in kit) inside boot and use the remainder to repack the tripot housing.

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Fig. 21: Sliding Tripot Housing Over Tripot Spider Assembly On Shaft Courtesy of GENERAL MOTORS CORP.

8. Install the large clamp over the large diameter of the boot.

9. Slide the tripot housing over the tripot spider assembly on the shaft.

10. Slide the large diameter of the boot over the outside of the tripot housing and position the lip of the boot in the housing groove.

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Fig. 22: Installing Large Boot & Retaining Clamp Courtesy of GENERAL MOTORS CORP.

11. Place the large boot retaining clamp around the boot and close usingSA9161C Axle Boot Clamp Installer, (or equivalent). See Special Tools.

12. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement.

WHEEL DRIVE SHAFT OUTER JOINT AND SEAL REPLACEMENT

Tools Required

� SA9161C Drive Axle Boot Clamp Pliers. See Special Tools.

� SA9203C Axle Boot Clamp Installer. See Special Tools.

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Disassembly Procedure

1. Remove the wheel drive shaft from the vehicle. Refer to Wheel Drive Shaft Replacement.

Fig. 23: Clamping Drive Axle Shaft In Vice Courtesy of GENERAL MOTORS CORP.

2. Clamp the drive axle a shaft in a vice.

NOTE: Use soft metal or wood in between vice jaws to protect the shaft.

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Fig. 24: Using Hammer & Chisel To Disengage Outer Band From Inner Band At Retainer Peg On Large & Small Boot Clamps Courtesy of GENERAL MOTORS CORP.

3. Use a hammer and chisel to disengage the outer band from the inner band at the retainer peg on large and small boot clamps. Discard the clamps.

4. Separate the joint boot from the CV joint race at the large diameter.

5. Slide the boot away from the joint along the axle shaft.

6. Wipe the excess grease from the face of the CV inner race.

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Fig. 25: Separating CV Joint From Axle Shaft Courtesy of GENERAL MOTORS CORP.

7. Using a rubber mallet, or a hammer and a block of wood, carefully tap on the CV joint to remove it from the axle.

8. Remove the boot from the axle shaft.

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Fig. 26: Taping Gently On Brass Drift With A Hammer In Order To Tilt Cage Courtesy of GENERAL MOTORS CORP.

9. Place a brass drift against the CV joint cage (1).

10. Tap gently on the brass drift with a hammer in order to tilt the joint cage (1).

11. Remove the first chrome alloy ball (2) when the CV cage tilts.

12. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2).

13. Repeat the process in steps 8 through 11 to remove all 6 of the chrome alloy balls.

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Fig. 27: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage Courtesy of GENERAL MOTORS CORP.

14. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race.

15. Lift out the cage (4) and the inner race.

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Fig. 28: View Of Inner Race & Cage Courtesy of GENERAL MOTORS CORP.

16. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward.

17. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminants.

� The inner and outer race assemblies

� The CV joint cage

� The chrome alloy balls

18. Dry all the parts.

19. Check the CV joint assembly for the following items:

� Unusual wear

� Cracks

� Damage

20. Replace any damaged parts.

21. Clean the half shaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves).

Installation Procedure

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Fig. 29: Installing Seal Clamp On Neck Of Seal Courtesy of GENERAL MOTORS CORP.

1. Install the new swage ring (2) on the neck of the outboard seal (1). Do not swage.

2. Slide the outboard boot seal (1) onto the half shaft bar and position the neck of the outboard seal (1) in the seal groove on the half shaft bar. The largest groove below the sight groove on the half shaft bar is the seal groove seal (3).

IMPORTANT: Check clamp location during crimp operation to make sure that it is properly positioned around the entire circumference.

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Fig. 30: Clamping Swage Ring With Axle Boot Clamp Installer Courtesy of GENERAL MOTORS CORP.

3. Swage the swage ring with SA9161C Axle Boot Clamp Installer, (or equivalent). See Special Tools.

4. Measure the swage end gap dimension and repeat step (3) if necessary. The gap should not exceed 2.15 mm (0.85 in).

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Fig. 31: View Of Inner Race & Cage Courtesy of GENERAL MOTORS CORP.

5. Put a light coat of grease from the service kit on the ball groves in the inner race and outer race.

6. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage.

Fig. 32: View Of Outer Race, Inner Race, Cage Window & CV Joint Cage Courtesy of GENERAL MOTORS CORP.

7. Hold the cage and inner race 90 degrees to the center line of the outer race (1) and align the cage windows (3) with the lands of the outer race.

8. Place the cage and the inner race into the outer race.

9. Insert the first chrome ball, then tilt the cage in the opposite direction to insert the opposing ball.

IMPORTANT: Be sure that the retaining ring side of the inner race faces the half shaft bar.

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10. Repeat this process until all 6 balls are in place.

11. Place approximately half the grease from the service kit inside the outboard boot seal and pack the CV joint with the remaining grease.

Fig. 33: Installing Large Diameter End Of Boot & Retaining Clamp Onto CV Joint Housing Courtesy of GENERAL MOTORS CORP.

12. Push the CV joint onto the half shaft bar until the retaining ring is seated in the groove on the half shaft bar.

13. Slide the large diameter of the boot over the outside of the CV race and locate the lip of the boot in the housing groove.

14. Slide the large retaining clamp over the boot.

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Fig. 34: Latching Large Seal Retaining Clamp Courtesy of GENERAL MOTORS CORP.

15. Align the following items while latching:

1. The wheel drive shaft outboard seal (1)

2. The tripot housing

3. The large seal retaining clip (2)

16. Using theSA9203C Axle Boot Clamp Installer (1), latch the large seal retaining clamp (2). See Special Tools. Ensure that the latching tangs are fully engaged in the large seal clamp band.

17. Remove the wheel drive shaft from the bench vise.

18. Distribute the grease within the outer CV joint by plunging the joint back and fourth four to five times.

19. Inspect the outer CV joint and wheel drive shaft for smooth operation.

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� Hold the wheel drive shaft vertically, with the outer joint at the bottom.

� Rotate the wheel drive shaft four or five times in a circular motion.

20. To install the wheel drive shaft to the vehicle, refer to Wheel Drive Shaft Replacement.

DESCRIPTION AND OPERATION

WHEEL DRIVE SHAFTS DESCRIPTION AND OPERATION

The drive axle assemblies used on Saturn vehicles consist of a tripot joint and an outer constant velocity (CV) joint, connected by an axle shaft. Joints are used on the axle shafts to provide flexibility, since the axle assemblies must be able to move in response to suspension travel motion and steering inputs. The outer CV joint can swivel, while the tripot joint has the ability to both swivel and move in and out.

The drive axle is a serviceable assembly; the outer CV and inner tripot joints can be replaced. Although the drive axles do not require regular maintenance, they should be inspected periodically for damage and wear, particularly the axle boot.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

Special Tools Illustration Tool Number/Description

J 44015 Steering Linkage Installer

SA91100C Tie Rod Separator

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SA9161C Axle Boot Clamp Installer

SA9198C C/V Joint Snap Ring Pliers

SA9203C Axle Clamp Installer

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2005 axle shafts

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