Front-Wheel-Drive (Transaxle and CV Joint) Service

1. Front-Wheel-Drive (Transaxle and CV Joint) Service Chapter 78

2. Objectives • Diagnose CV joint problems • Service CV joints • Replace CV joint boots • Disassemble and repair transaxles

3. Introduction • Removal, service, and replacement of front drive axles and constant velocity (CV) joint • Lucrative service area • Transaxle removal • Relatively straightforward • Once axle removal is accomplished

4. Transaxle and Front-Wheel-Drive Service and Repair • Checks of the axle assemblies • Some can be made with the axle on the car

5. Leaking CV Joint Boot • Front-wheel-drive axles • Require service as a vehicle ages • Some checks and services can be made with axle on vehicle • Others require removal and disassembly of components

6. CV Joint Boot Service • Boots age over time • Repeated flexing and exposure to elements • Boot fails • Grease leaks out • If not replaced: entire joint will fail • Most common problem with CV joints • Replacement boot kits • Come with new clamps and correct amount of high pressure grease

7. Axle Inspection and Diagnosis • Check halfshaft for obvious looseness • Noises can be detected from the test drive • Weight must be on the suspension when checking for a noise • Questions to ask customer: • What does the noise sound like? • Does it occur during acceleration, deceleration, or when turning?

9. CV Joint Diagnosis • Clicking sound during a turn • Indicates bad outboard joint • Always check the splines on a shaft • Bad plunge joint makes clunking sound • Starting from a stop • During deceleration • Braking • Excess wear • Hard to detect visually

10. Axle Shaft Removal • Major steps • Loosen axle nut • Remove the stub shaft from the hub • Remove the stub shaft • Remove the axle • Remove snap rings and clips • Remove boot

12. CV Joint Replacement • Internal circlip • Common way of retaining a fixed joint to shaft • Called knock-off-type joint • Different version used in some Japanese vehicles • CV joint has been removed from axle • Boot is removed • Fixed Rzeppa joints • Held to their shafts by external snap ring or internal clip

13. Fixed Joint Disassembly and Inspection • Major steps • Use drift punch to move inner race to the side for a more complete inspection • Wipe the parts off and look for wear • Disassemble Rzeppa joint • Mark all major components • Remove the balls • Wipe and lightly grease • Install the boot and joint

14. CV Joint Boot Clamps • Several types • Universal clamp • Bridge-type clamp • Earless clamp • Pressed-fit ring • Installing small-end clamp • Pull big end of the boot over CV joint and install retaining clamp • Vent the small end of the boot

16. Servicing an Inner Tripod Joint • Major steps • Before removing: tape shaft and joint • Cut away the clamps and boot • Check to see if tripod rollers come off of spider • Inspect condition of inside tulip • Align any marks • After boot and tripod are reinstalled: grease rollers and fill boot with rest of grease

17. Double Offset Plunge Joints • Vary in how they are connected to axle shaft • Most held by internal circlip • Joint must be disassembled before it can be removed • Other kind has a circlip that can be removed by pounding on outer housing • Metal retaining ring holds parts in the housing

18. Cross Groove Joint Serviceand Rebuilt Halfshafts • Key points • Cross groove joint is serviced in similar manner to Rzeppa joints • Disassembled by turning inner race and cage perpendicular to outer cage and removing them • Complete rebuilt halfshaft is a popular repair • Installing rebuilt halfshafts is often in the best interest of the customer

19. Installing the Axle • Major steps • To install a spline-type joint into transaxle: push in on axle while turning it to align splines • After inner end is installed: position stub shaft into hub as far as it can go • Do not forget to torque ball joint stud bolt • When vehicle is back on ground: torque new stub shaft nut • Check clearance of boot clamps before test-driving

20. Transaxle Repair and Removal • Key points • Transaxles used with transverse engines • Differential gears are helical gears • No pinion depth or backlash adjustments • Front-wheel-drive vehicles • Easier to pull engine with transaxle • Support the engine if it is easier to leave it in the vehicle • Unbolt transaxle from engine • Axles are pulled in manner previously described

22. Manual Transaxle Repair • Key points • Separate halves of case on a transaxle • Check service manual for any specifics • Service and assembly are similar to RWD transmissions • End play of gears is checked with feeler gauge or dial indicator • Thrust washers, shims, or snap rings can be used to make adjustments

23. Automatic Transaxle Repair • Automatic transaxle repair • Same as RWD automatic transmissions • Differences • Gar or a chain is driven by transmission output shaft to turn differential section • Automatic transaxles have a differential

24. Transaxle Differential Side Bearing Adjustment • Case halves are reassembled • Differential side bearing preload is adjusted • Some use special tools

25. Install the Transaxle • Installation of transaxle is the reverse of removal sequence • After installation: be sure to check transaxle lubricant level • Some have a fill plug on the side • Some have a dipstick • Others require removal of speedometer gear