Published: 09-Jun-2011

Front Drive Halfshafts -

General Specification
Item Specification
Type Fully floating, solid shafts with inner and outer constant velocity joints
Recommended Lubricant
Item Specification
Front drive halfshaft Weicon anti-seize grease
Outboard joint Use grease supplied with replacement boot kit
Inboard joint Use grease supplied with replacement boot kit
Torque Specifications
Description Nm lb-ft
Extension shaft bearing anchorage to transmission bolts 65 48
Extension shaft bearing anchorage to block bolts 65 48
Extension shaft bearing clamp to anchorage nuts 24 18
Front halfshaft to hub nut*
Stage 1 120 89
Stage 2 Then a further 60 degrees Then a further 60 degrees
Shaft bearing anchorage adolf washer to sump casting - 2.0L 4 3
* New nuts/bolts must be installed

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 Published: 23-Jul-2012
Front Drive Halfshafts - Front Halfshaft LH
Removal and Installation

Special Tool(s)
205-857
Remover, Halfshaft

Removal
CAUTIONS:

Nuts and bolts must be tightened with the weight of the vehicle on the suspension.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Make sure the halfshaft constant velocity (CV) joints do not over articulate. Failure to follow this instruction may

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result in damage to the CV joints.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. CAUTION: Discard the nut.

4.

5. CAUTIONS:

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Do not use air tools to remove the nut.

Discard the nut.

6. CAUTION: Discard the bolt.

 8.
7.

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 9. CAUTIONS:

Make sure that the driveshaft is supported with

suitable retaining straps.

Do not use a hammer to detach the halfshaft from

the hub assembly, failure to follow this instruction may
result in damage to the halfshaft.

Special Tool(s): 205-857

10. WARNING: Be prepared to collect escaping fluids.

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CAUTION: Keep the halfshaft horizontal to avoid
damaging the oil seal.

11. CAUTION: Discard the snap ring.

 12. CAUTION: Inspect the seal, replace if damaged

NOTE: Automatic transmission shown, manual is

similar.

Installation

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1. NOTES:

Automatic transmission shown, manual is similar.

This step is only required if previously removed.

2. NOTES:

Manual transmission shown, automatic is similar

Do not fully engage the halfshaft until the oil seal

protector has been removed.

To prevent oil seal damage use the protector when

installing the shaft into the transmission. It is not a
special tool but is available from the Parts Catalogue.
3. CAUTIONS:

Make sure that the snap ring is installed from the

end of the halfshaft. Failure to follow this instruction
may result in damage to the vehicle.

Install a new snap ring.

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4. CAUTION: Keep the halfshaft horizontal to avoid
damaging the oil seal.

NOTES:

Manual transmission shown, automatic is similar

Do not fully engage the halfshaft until the oil seal

protector has been removed.
 6.
5.

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7. Torque: 110 Nm

8. CAUTION: Make sure that a new bolt is installed.

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Torque: 200 Nm

9. WARNING: Make sure that a new nut is installed.

CAUTIONS:

Do not use air tools to install the nut. Failure to

follow this instruction may result in damage to the
component.

Install the halfshaft nut finger tight.

Tighten the nut without the weight of the vehicle

on the suspension.

Torque:
Stage 1:120 Nm
Stage 2:60°
 10. Torque: 10 Nm

11. WARNING: Make sure that a new nut is installed.

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Torque: 60 Nm

12. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
 13. Manual transmission vehicles only: Check and top-up the
transmission fluid level.

14. Check the wheel alignment and adjust as necessary.

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 Published: 18-Sep-2013
Front Drive Halfshafts - Front Halfshaft RH LHD AWD/RHD AWD
Removal and Installation

Special Tool(s)
205-857
Remover, Halfshaft

Removal
CAUTIONS:

Nuts and bolts must be tightened with the weight of the vehicle on the suspension.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Make sure the halfshaft constant velocity (CV) joints do not over articulate. Failure to follow this instruction may

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result in damage to the CV joints.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. CAUTION: Discard the nut.

4.

5. CAUTIONS:

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Do not use air tools to remove the nut.

Discard the nut.

6. CAUTION: Discard the bolt.

 8.
7.

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 9. CAUTIONS:

Make sure that the driveshaft is supported with

suitable retaining straps.

Do not use a hammer to detach the halfshaft from

the hub assembly, failure to follow this instruction may
result in damage to the halfshaft.

Special Tool(s): 205-857

10.

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11. WARNING: Be prepared to collect escaping fluids.

CAUTION: Keep the halfshaft horizontal to avoid

damaging the oil seal.
 12.

Installation

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1. CAUTION: Keep the halfshaft horizontal to avoid
damaging the oil seal.
2. CAUTION: LH illustration shown, RH is similar.

3. CAUTION: Make sure that the halfshaft bearing is

correctly located in the support bracket before installing

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the retaining nuts.

Torque: 25 Nm
4.

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5. Torque: 110 Nm
6. CAUTION: Make sure that a new bolt is installed.

Torque: 200 Nm

7. WARNING: Make sure that a new nut is installed.

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CAUTIONS:

Do not use air tools to install the nut. Failure to

follow this instruction may result in damage to the
component.

Install the halfshaft nut finger tight.

Tighten the nut without the weight of the vehicle

on the suspension.

Torque:
Stage 1:120 Nm
Stage 2:60°

8. Torque: 10 Nm
 9. WARNING: Make sure that a new nut is installed.

Torque: 60 Nm

10. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

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11. Check the wheel alignment and adjust as necessary.
 Published: 09-Jun-2011
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal and Installation

Special Tool(s)
303-D121
Puller, General Purpose

General Equipment
Vise

Removal

NOTE: RH inner constant velocity joint boot shown, LH is similar.

1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal

and Installation).
Refer to: Front Halfshaft RH - LHD AW D/RHD AWD (205-04 Front

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Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - FWD (205-04 Front Drive Halfshafts,
Removal and Installation).

2. NOTE: Discard the retaining clips.

General Equipment: Vise

3. CAUTION: Make sure that filings and swarf do not
enter the component.

NOTE: Some variation in the illustrations may

occur, but the essential information is always correct.

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4. NOTE: Discard the retaining clip.
 5. Special Tool(s): 303-D121

Installation

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1. CAUTION: Extreme cleanliness must be exercised when
handling these components.

Clean and inspect the components for deterioration.

2.

3. NOTE: Install a new retaining clip.

 4. CAUTION: Make sure that these components are
installed to the noted removal position.

5. Pack the inner CV joint with the grease supplied.

6. NOTE: Install new retaining clips.

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7. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal
and Installation).
Refer to: Front Halfshaft RH - LHD AW D/RHD AWD (205-04 Front
Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - FWD (205-04 Front Drive Halfshafts,
Removal and Installation).
 Published: 09-Jun-2011
Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Installation

General Equipment
Vise

Removal

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Inner Constant Velocity (CV) Joint Boot (205-04 Front Drive
Halfshafts, Removal and Installation).

3. NOTE: Discard the retaining clips.

General Equipment: Vise

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Installation

1. CAUTION: Extreme cleanliness must be exercised when

handling these components.

Clean and inspect the components for deterioration.

2. Pack the outer CV joint with the grease supplied.

3. NOTES:

Install new retaining clips.

Some variation in the illustrations may occur, but

the essential information is always correct.

4. Refer to: Inner Constant Velocity (CV) Joint Boot (205-04 Front Drive
Halfshafts, Removal and Installation).

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 Published: 18-Sep-2013
Front Drive Halfshafts - Front Halfshaft RH FWD
Removal and Installation

Special Tool(s)
205-857
Remover, Halfshaft

Removal
CAUTIONS:

Nuts and bolts must be tightened with the weight of the vehicle on the suspension.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Make sure the halfshaft constant velocity (CV) joints do not over articulate. Failure to follow this instruction may

cardiagn.com
result in damage to the CV joints.

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

3. CAUTION: Discard the nut.

4.

5. CAUTIONS:

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Do not use air tools to remove the nut.

Discard the nut.

6. CAUTION: Discard the bolt.

 8.
7.

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 9. CAUTIONS:

Make sure that the driveshaft is supported with

suitable retaining straps.

Do not use a hammer to detach the halfshaft from

the hub assembly, failure to follow this instruction may
result in damage to the halfshaft.

Special Tool(s): 205-857

10.

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11. WARNING: Be prepared to collect escaping fluids.

CAUTION: Keep the halfshaft horizontal to avoid

damaging the oil seal.
 12. CAUTION: Inspect the seal, replace if damaged

Installation

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1. NOTE: This step is only required if previously
removed.

2. CAUTION: Keep the halfshaft horizontal to avoid damaging the

oil seal.
3. CAUTION: LH illustration shown, RH is similar.

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4. CAUTION: Make sure that the halfshaft bearing is
correctly located in the support bracket before installing
the retaining nuts.

Torque: 25 Nm
5.

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6. Torque: 110 Nm
7. CAUTION: Make sure that a new bolt is installed.

Torque: 200 Nm

8. WARNING: Make sure that a new nut is installed.

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CAUTIONS:

Do not use air tools to install the nut. Failure to

follow this instruction may result in damage to the
component.

Install the halfshaft nut finger tight.

Tighten the nut without the weight of the vehicle

on the suspension.

Torque:
Stage 1:120 Nm
Stage 2:60°

9. Torque: 10 Nm
 10. WARNING: Make sure that a new nut is installed.

Torque: 60 Nm

11. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).

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12. Check and top-up the transmission fluid level.

13. Check the wheel alignment and adjust as necessary.